Biosensor with laser-sealed capillary space and method of making

ABSTRACT

A test strip or biosensor comprising a base substrate on which an electrode system is formed. One or more laminate layers overlie the base substrate to form a sample-receiving chamber in which a reagent is deposited. An opening is provided from the sample-receiving chamber to the exterior of the biosensor. The layers and the base substrate are laser welded to secure the biosensor. One of the layer and base substrate is light transmissive to allow laser welding at the interface therebetween. The biosensor may be formed from a series of continuous webs that are subsequently sliced to form individual biosensors.

RELATED APPLICATIONS

This application is a continuation-in-part of U.S. patent application Ser. No. 10/872,027, filed Jun. 18, 2004, which claims the benefit of U.S. Provisional Patent Application No. 60/480,397, filed Jun. 20, 2003, which are hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates generally to the testing of body fluids for concentration of analytes and more particularly to a test strip or biosensor for such testing.

BACKGROUND

Test strips are often used to measure the presence and/or concentrations of selected analytes in test samples. For example, a variety of test strips are used to measure glucose concentrations in blood to monitor the blood sugar level of people with diabetes. These test strips include a reaction chamber into which a reagent composition has been deposited. Current trends in test strips require smaller test samples and faster analysis times. This provides a significant benefit to the patient, allowing the use of smaller blood samples that can be obtained from less sensitive areas of the body. Additionally, faster test times and more accurate results enable patients to better control their blood sugar level.

In connection with smaller sample volumes, it is known to provide test strips having a sufficiently small reaction chamber such that sample fluid is drawn therein by capillary action, which is a phenomenon resulting from the surface tension of the sample fluid and the thermodynamic tendency of a liquid to minimize its surface area. For example, U.S. Pat. No. 5,141,868 discloses a test strip having a cavity sized sufficiently small to draw sample liquid therein by capillary action. The cavity is defined by two parallel plates spaced about 1 mm apart by two epoxy strips extending lengthwise along lateral sides of the plates. The cavity is open at both ends, one of which receives the sample, and the other of which allows air to escape. The cavity includes an electrode structure and carries a coating of a material appropriate to the test to be performed by the test strip.

Various other test strip designs include capillary cavities that draw sample fluid therein and include vent openings to allow air to escape. As one should appreciate, capillary channels in current test strip designs are typically very small and are continually being designed smaller to reduce the amount of sample needed for testing. However, the smaller the capillary entrance width, the more difficult it becomes to accurately apply (or “target”) a small sample volume to the capillary of the test strip. Targeting is even more important in segments of the demographic with impaired vision and/or reduced dexterity because it is more difficult for this segment to accurately align their fingers with the dosing edge of a test strip. Furthermore, the sample fluid sometimes undesirably hesitates before being drawn into the capillary, a phenomenon referred to as “dose hesitation.” It would be desirable to overcome the difficulties associated with small capillaries in test strip design.

A limitation of electrochemical methods of measuring the concentration of a chemical in blood is the effect of confounding variables on the diffusion of analyte and the various active ingredients of the reagent. Examples of limitations to the accuracy of blood glucose measurements include variations in blood composition or state (other than the aspect being measured). For example, variations in hematocrit (concentration of red blood cells) can effect the signal generation of a blood sample. The utility of a reported blood glucose response after a short test time is questionable in applications where the results are not compensated for other sample variables or interferents such as hematocrit and temperature.

With respect to hematocrit in blood samples, prior art methods have relied upon the separation of the red blood cells from the plasma in the sample, by means of glass fiber filters or with reagent films that contain pore-formers that allow only plasma to enter the films, for example. Separation of red blood cells with a glass fiber filter increases the size of the blood sample required for the measurement, which is contrary to test meter customer expectations. Porous films or membranes are only partially effective in reducing the hematocrit effect, and must be used in combination with increased delay time and/or specialized measurement techniques to achieve the desire accuracy. Thus, it is desirable to manufacture a biosensor that is capable of reducing hematocrit interference in an easy, simple, and cost-effective manner.

Adhesives are typically used to join or seal together various layers of test strips. For high volume production of test strips, adhesives can be a significant cost both as a raw material and especially with respect to manufacturing costs. For instance, several manufacturing processes can be detrimentally affected by the adhesives. As an example, slitters, which are used to cut a web to form the strips, can be gummed up over time as a result of a build up of adhesive sawdust. As a result, the slitters must be shut down periodically for cleaning. This periodic interruption of production results in lower production rates. Thus, it is desirable to manufacture test strips in an inexpensive manner.

SUMMARY OF THE INVENTION

The present invention provides a test strip with a sample receiving chamber having a novel flared portion that terminates in a sample receiving opening. The flared portion provides a reservoir from which sample fluid can be drawn into the capillary or sample receiving chamber, aids the user in introducing the sample to the test device, and reduces dose hesitation. In preferred embodiments, the hydrophilic reagent layer extends to the dosing end or side of the test strip and further promotes wicking of the sample into the sample receiving chamber and thus further reduces dose hesitation.

In one form thereof, the present invention provides a test strip comprising a base substrate and a covering layer overlying the base substrate, the covering layer further comprising a vent. A spacing layer is disposed between the covering layer and the base substrate, and the spacing layer has a void that defines a sample receiving chamber disposed between the base substrate and the covering layer. The sample receiving chamber defines a flared portion that terminates in a fluid receiving opening. The vent is in communication with the sample receiving chamber, whereby air can escape from the vent as fluid is drawn into the sample receiving chamber.

In a preferred form thereof, the covering layer, the base substrate and the spacing layer are substantially flat, such that the sample receiving chamber comprises a substantially constant height and a width that varies at the flared portion. More preferably, the sample receiving chamber includes an elongated portion having a substantially constant width extending inwardly from the flared portion. The covering layer and the base substrate include substantially aligned edges that comprise a fluid receiving end or side of the test strip at which the fluid receiving opening is located.

In a preferred form, the aligned edges comprise a notch which further defines the opening. The notch is smaller than the flared portion and is disposed centrally with respect to the flared portion.

In another preferred form, at least one electrode and a reagent layer are disposed in the sample receiving chamber, and the reagent layer covers at least one electrode. Most preferably, the reagent layer extends to the sample receiving opening.

In another preferred form, the present invention provides a test strip comprising a base substrate having a reagent layer disposed thereon. A covering layer overlies the base substrate and a sample receiving chamber is disposed between the base substrate and the covering layer. The sample receiving chamber comprises a flared portion defining a sample receiving opening, and the reagent layer extends to the sample receiving opening.

In a preferred form thereof, the test strip includes a slot in communication with the sample receiving chamber, the slot defining a vent opening in the covering layer that allows air to escape as fluid enters the sample receiving chamber. The sample receiving chamber comprises an elongated portion extending inwardly from the flared portion. The flared portion is defined by a pair of opening walls that narrow in a direction toward the elongated portion, whereas the elongated portion is defined by substantially parallel walls that are connected by an end wall.

In another form thereof, the present invention provides a method of making a test strip. A base substrate, a spacing layer and a covering layer are provided. A void is formed in the spacing layer, the void having an elongated portion and a bulbous portion. The spacing layer is laminated to the base substrate and the covering layer is laminated to the spacing layer, thereby forming a test strip precursor. A cut is made through the precursor to make the test strip, the cut crossing the bulbous portion of the void and forming a sample receiving edge of the test strip, wherein the void defines a sample receiving chamber having a flared portion terminating in a sample receiving opening at the sample receiving edge of the test strip.

In a preferred form of this inventive method, the sample receiving edge comprises an end of the test strip, the sample receiving opening is flared outwardly, and the dosing end of the test strip is tapered.

The present invention provides a very easy-to-dose test strip and provides a robust but flexible manufacturing process. The various other features that characterize the invention are pointed out with particularity in the attached claims.

Another aspect concerns a biosensor that includes a base substrate and at least one cover layer overlying the base substrate. The base substrate and the cover layer cooperate to define a sample-receiving chamber therebetween. A reagent is positioned within the sample-receiving chamber. The base substrate and the cover layer further cooperate to provide an opening for the sample-receiving chamber along an edge of the biosensor. The base substrate and the cover layer are laser welded to define the sample-receiving chamber.

A further aspect concerns a biosensor that includes a base substrate and a cover layer. One or more laser welds in cooperation with the base substrate and the cover layer define a micro-capillary chamber sized to reduce hematocrit interference in a blood sample. A reagent is disposed within the micro-capillary chamber to analyze the blood sample.

Another aspect concerns a biosensor that includes a spacer positioned between the base substrate and the cover layer for further defining the sample-receiving chamber. The spacer and base substrate are laser welded and the cover layer and spacer are laser welded, simultaneously or sequentially. A reagent is positioned within the sample-receiving chamber.

Still yet another aspect concerns a method in which a reagent is deposited on a base substrate. The base substrate and a cover layer and optionally a spacing layer are laser welded together to form a sample-receiving chamber of a biosensor that contains the reagent.

For a better understanding of the invention, its advantages, and objectives obtained therefrom, reference should be made to the drawings and to the accompanying description, in which there is illustrated and described preferred embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Referring now to the drawings, wherein like reference numerals and letters indicate corresponding structure throughout the several views:

FIG. 1 is a perspective view of a test strip or biosensor in accordance with the present invention.

FIG. 1A is an enlarged fragmentary perspective view of the test strip shown in FIG. 1, illustrating one embodiment of the novel vent opening or slot.

FIG. 1B is an enlarged fragmentary perspective view illustrating an alternate embodiment of the vent opening or slot in accordance with the present invention.

FIG. 1C is an enlarged fragmentary perspective view illustrating another alternate embodiment of the vent opening or slot and also illustrating an alternate configuration of the opening to the sample receiving chamber of the biosensor in accordance with the present invention.

FIG. 2 is an exploded, perspective view of the biosensor of FIG. 1.

FIG. 3 is a cross-sectional view of a portion of the biosensor of FIG. 1, additionally illustrating adhesive layers that have been omitted from FIGS. 1-2.

FIG. 4 is a top, plan view of a portion of the biosensor of FIG. 1, with portions broken away to show underlying details.

FIGS. 5 and 5A show a process flow diagram for a method for producing a biosensor in accordance with the present invention.

FIG. 6 is a perspective view showing the reel-to-reel processing and cutting of a web material useful in forming the bottom substrate of the biosensor of the present invention.

FIG. 7 is a perspective view of a portion of a webbing, showing an exemplary pattern of electrical components on the base substrate.

FIG. 8 is a perspective view of a portion of the webbing of FIG. 7 and including a reagent composition coated thereon.

FIG. 9 is an exploded, perspective view showing a spacing layer and the associated adhesive layers and release liners.

FIG. 10 is an exploded perspective view of a portion of the spacing layer with pre-capillary chambers cut out and the spacing layer being aligned for lamination to a base substrate having electrode patterns thereon.

FIG. 11 is a perspective view of an assembly of the base substrate with the spacing layer.

FIG. 12 is an exploded, perspective view showing the combination of the body and chamber covers for assembly onto the base substrate and spacing layer.

FIG. 13 is a perspective view of a portion of an assembly including the several layers comprising the biosensor.

FIG. 14 is a perspective view of a portion of webbing including several detachable biosensors.

FIG. 15 is a perspective view of a single biosensor separated from the assembled webbing.

FIG. 16A is a top view of a single biosensor separated from assembled webbing.

FIG. 16B is a fragmentary top view of a web or test strip precursor illustrating a void with a flared end that will ultimately form the sample receiving chamber for a biosensor such as that shown in FIG. 16A.

FIG. 16C is a fragmentary top view of a web or test strip precursor illustrating a light bulb shaped void that will ultimately form the sample receiving chamber for a biosensor such as that shown in FIG. 16A.

FIG. 17A is a top view of a single biosensor separated from assembled webbing.

FIG. 17B is a fragmentary top view of a web or test strip precursor illustrating a chalice shaped void that will ultimately form the sample receiving chamber for a biosensor such as that shown in FIG. 17A.

FIG. 17C is a fragmentary top view of a web or test strip precursor illustrating a keyhole shaped void that will ultimately form the sample receiving chamber for a biosensor such as that shown in FIG. 17A.

FIG. 18A is a top view of a single biosensor separated from assembled webbing.

FIG. 18B is a fragmentary top view of a web or test strip precursor illustrating a T-shaped void that will ultimately form the sample receiving chamber for a biosensor such as that shown in FIG. 18A.

FIG. 18C is a fragmentary top view of a web or test strip precursor illustrating a T-shaped void that will ultimately form the sample receiving chamber for a biosensor such as that shown in FIG. 18A.

FIG. 19A is a fragmentary top view of a single test strip illustrating a Y-shaped flared portion leading inwardly from a straight dosing edge of the test strip to an elongated portion.

FIG. 19B is a fragmentary top view of a single test strip illustrating a curved profile for a dosing edge and a curved shaped flared portion leading inwardly on the test strip to an elongated portion.

FIG. 19C is a fragmentary top view of a single test strip illustrating a curved concave profile for a dosing edge and a Y-shaped flared portion leading inwardly on the test strip to an elongated portion.

FIG. 20 is a flow diagram for a biosensor manufacturing technique that utilizes laser welding according to one embodiment.

FIG. 21 is an exploded view of a biosensor web assembled in accordance with the technique illustrated in FIG. 20.

FIG. 22 is an enlarged view of a first biosensor laser welded in accordance with the technique illustrated in FIG. 20.

FIG. 23 is an enlarged view of a second biosensor laser welded in accordance with the technique illustrated in FIG. 20.

FIG. 24A is a flow diagram for a biosensor manufacturing technique that utilizes laser welding according to another embodiment.

FIG. 24B is a flow diagram for a biosensor manufacturing technique that utilizes laser welding according to yet another embodiment.

FIG. 24C is a flow diagram for a biosensor manufacturing technique that utilizes laser welding according to yet another embodiment.

FIG. 25 is an exploded view that shows a spacer layer being applied to a web of base substrate material.

FIG. 26A is a bilaminate biosensor.

FIG. 26 B is a diagrammatic view of a laser welding system for a trilaminate biosensor.

FIG. 27 is a cross-sectional view of a drum assembly used in the laser welding system in FIG. 26.

FIG. 28 is a perspective view of the drum assembly in FIG. 27.

FIG. 29 is a front view of a variation of the laser welding system in FIG. 26.

FIG. 30 is an enlarged perspective view of the laser welding system in FIG. 29.

FIG. 31 is a top view of a first tri-laminate biosensor.

FIG. 32 is a top view of a second tri-laminate biosensor.

FIG. 33 is an exploded view of the first tri-laminate biosensor in FIG. 31.

FIG. 34 is a perspective view of a roll of a base substrate web.

FIG. 35 is an enlarged view of the base substrate web in FIG. 34.

FIG. 36 is a perspective view of a roll of a spacer web.

FIG. 37 is an enlarged view of the spacer web in FIG. 36.

FIG. 38 is a perspective view of a roll of a cover layer web.

FIG. 39 is an enlarged view of the cover layer web in FIG. 38.

FIG. 40 is a top view of a laminate that includes the spacer web of FIG. 36 overlaying the base substrate web of FIG. 34 during assembly.

FIG. 41 is a top view of the cover layer web of FIG. 38 overlaying the laminate of FIG. 40 during assembly.

FIG. 42 is a top view of the laminate of FIG. 41 that shows laser weld regions.

FIG. 43 is a top view of a web of biosensors resulting from the laminate in FIG. 42.

FIG. 44 is an exploded view of a third tri-laminate biosensor.

FIG. 45 is a top view of the third tri-laminate biosensor that shows its laser welded regions.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the specific embodiments illustrated herein and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. Any alterations and further modifications in the described processes or devices, and any further applications of the principles of the invention as described herein, are contemplated as would normally occur to one skilled in the art to which the invention relates.

System

The present invention relates to a system that is useful for assessing an analyte in a sample fluid. The system includes devices and methods for evaluating the sample fluid for the target analyte. As more fully described hereafter, the evaluation may range from detecting the presence of the analyte to determining the concentration of the analyte. The analyte and the sample fluid may be any for which the test system is appropriate. For purposes of explanation only, a preferred embodiment is described in which the analyte is glucose and the sample fluid is blood or interstitial fluid. However, the present invention clearly is not so limited in scope.

Sensor

One component of the system is an electrochemical sensor including a sample-receiving chamber for the sample fluid, and a suitable reagent for producing an electrochemical signal in the presence of the test analyte. The sensor preferably comprises a disposable test strip, particularly one having a laminar construction providing an edge opening which communicates with the sample-receiving chamber. The reagent is disposed within the sample-receiving chamber in position to provide the electrochemical signal to a working electrode also positioned within the chamber. In appropriate circumstances, such as for glucose detection, the reagent may contain an enzyme and optionally a mediator.

Meter

The sensor is used in combination with a meter for determination of the analyte in the sample fluid. The meter conventionally includes a connection with the electrodes of the sensor and circuitry to evaluate the electrochemical signal corresponding to the concentration of the analyte. The meter may also include means for determining that the sample fluid has been received by the sensor, and that the amount of sample fluid is sufficient for testing. The meter typically will store and display the results of the analysis, or may alternatively provide the data to a separate device.

Analyte—Characteristic

The system can provide either a qualitative or quantitative indication for the analyte. In one embodiment, the system indicates simply the presence of the analyte in the sample fluid. The system may also provide a reading of the quantity or concentration of the analyte in the sample fluid. In a preferred embodiment, it is a feature of the present invention that a highly accurate and precise reading of the analyte concentration is quickly obtained from a small volume of sample fluid.

Analyte—Type

The system is useful for the determination of a wide variety of analytes. The test strip, for example, is readily adapted for use with any suitable chemistry that can be used to assess the presence of the analyte. Most preferably, the system is configured and used for the testing of an analyte in a biological fluid. Such analytes may include, for example, glucose, cholesterol, HDL cholesterol, triglycerides, lactates, lactate dehydrogenase, alcohol, uric acid, and 3-hydroxybutyric acid (ketone bodies). Commensurate modifications to the system will be apparent to those skilled in the art. For purposes of explanation, and in a particularly preferred embodiment, the system is described with respect to the detection of glucose in a biological fluid.

Interferants

Test methodologies may be variously affected by the presence of interferants in the sample fluid. For example, the testing for glucose in a blood sample may be impacted by such factors as oxygen, bilirubin, hematocrit, uric acid, ascorbate, acetaminophen, galactose, maltose, and lipids. The present system is adaptable to minimize or eliminate the adverse effects of interferants that may also be present in the sample fluid. These effects may be addressed by appropriate selection of test materials and parameters, such as by the selection of chemistries that are known to be impacted less, or not at all, by possible interferants. As is known in the art, other steps may also be taken to address possible interferant effects, such as the use of coatings or films that prevent the interferant from entering the test zone. In addition, modifications to the electrode configurations or interrogation methods can be used to minimize the effect of interferants.

Fluid Type

The system is useful with a wide variety of sample fluids, and is preferably used for the detection of analytes in a biological fluid. In this context, the term “biological fluid” includes any bodily fluid in which the analyte can be measured, for example, interstitial fluid, dermal fluid, sweat, tears, urine, amniotic fluid, spinal fluid and blood. The term “blood” in the context of the invention includes whole blood and its cell-free components, namely plasma and serum. In addition, the system is useful in connection with control fluids that are used in conventional fashion to verify the integrity of the system for testing.

In a preferred embodiment, the system is employed for the testing of glucose. The sample fluid in this instance may specifically include, for example, fresh capillary blood obtained from the finger tip or approved alternate sites (e.g., forearm, palm, ear lobe, upper arm, calf and thigh), fresh venous blood, and control solutions supplied with or for the system.

The fluid may be acquired and delivered to the test strip in any fashion. For example, a blood sample may be obtained in conventional fashion by incising the skin, such as with a lancet, and then contacting the test strip with fluid that appears at the skin surface. It is an aspect of the present invention that the test strip is useful with very small fluid samples. It is therefore a desirable feature of the invention that only a slight incising of the skin is necessary to produce the volume of fluid required for the test, and the pain and other concerns with such method can be minimized or eliminated.

It is also well known that different locations on the skin will produce more or less amounts of blood upon lancing. The finger tip, for example, is a commonly used site for obtaining a blood sample because it produces a relatively large amount of blood upon lancing. However, it is also known that areas that produce larger volumes of blood are generally associated with greater degrees of pain for the user. It is therefore an additional advantage of the present system that the required volume of sample fluid is sufficiently small that the test strip is useful with the amount of blood typically obtained upon lancing less productive, but also less painful, areas of the skin, such as the palm and upper arm. The use of these locations to obtain sample fluids for testing is sometimes referred to as “alternate site testing”. The present invention is particularly well suited to use with sample fluids, e.g., blood or interstitial fluid, obtained at these alternate sites.

Test Strip—General

Introduction.

The test strip includes several basic components. The strip comprises a small body defining a chamber in which the sample fluid is received for testing. This “sample-receiving chamber” is filled with the sample fluid by suitable means, preferably by capillary action, but also optionally assisted by pressure or vacuum. The sample-receiving chamber includes electrodes and chemistry suitable for producing an electrochemical signal indicative of the analyte in the sample fluid.

Basic Description.

Referring in particular to the drawings, there is shown a preferred embodiment of a test strip useful in accordance with the present invention. The test strip 10 includes a base substrate 12, a spacing layer 14 and a covering layer 16 comprising body cover 18 and chamber cover 20. The spacing layer 14 includes a void portion 22 to provide a sample-receiving chamber 24 extending between the base substrate 12 and the covering layer 16.

The base substrate 12 carries an electrode system 26 including a plurality of electrodes 28 and electrode traces 30 terminating in contact pads 32. The electrodes are defined as those portions of electrode traces 30 that are positioned within the sample-receiving chamber 24. Various configurations of the electrode system 26 may be used, as set forth hereafter. A suitable reagent system 33 overlies at least a portion of the electrodes or electrode pairs 28 within the sample-receiving chamber.

The body cover 18 and the chamber cover 20 overlying the spacing layer 16 define a slot 34 therebetween, the slot defining a vent opening communicating with the sample-receiving chamber to allow air to escape the chamber as a sample fluid enters the chamber from the edge opening or fluid receiving opening 35. The test strip therefore includes a dosing end 36 and a meter insertion end 38. The shape of the dosing end is typically distinguishable from the meter end so as to aid users. As shown in FIG. 1, preferably, dosing end 36 is tapered or narrowed to form a trapezoidal shape to aid users in aligning the sample-receiving chamber 24 of test strip 10 with a fluid sample. The tapered shape of the dosing end 36 minimizes the available contact surface of the dosing end to the user's skin, thereby aiding the alignment of the sample-receiving chamber 24 with the fluid sample, as described in more detail below.

In addition, strip graphics and contrasting colors at the dosing end are preferably used to further improve the intuitiveness of the strip design. Similarly, at the meter insertion end, chevron 31 indicates the direction of insertion of the strip into the meter. Further, chevron 31 is sized and positioned on the test strip 10 such that the chevron 31 is inside the meter, and therefore hidden from view, when the test strip 10 is properly inserted into the meter. The size and position of chevron 31 (as opposed to an arrow) lessens the likelihood that users will jam a test strip marked with the chevron 31 into the meter and damage or destroy the test strip 10.

General Dimensions.

The test strip is a relatively small device that is dimensioned for compactness and ease of storage and use. In a typical embodiment, the strip length is on the order of 20 to 50 mm, preferably about 33 to about 38 mm, in length, and 5 to 15 mm, preferably about 7 to about 9 mm, in width. The distance from the slot or vent opening 34 to the edge of the meter is sized to provide a “grab area” where there is no blood present, and to guard against blood contamination of the meter contact area, and therefore may be in the range of 5 to 35 preferably ≧13 mm. The length of the test strip portion (from the meter insertion end 38) that is inserted into the meter is preferably ≦6.0 mm along the long axis of the test strip.

The preferred laminar construction of the test strip also provides a device that is relatively thin. The minimal thickness of the strip allows ready packaging of the strip in appropriate containers that are convenient for the user. For example, the overall thickness of the test strip may be about 500 to 525 μm. The thickness of the test strip portion that is inserted into the meter contact may be about 250 μm.

Substrate

The test strip includes a base substrate 12 which comprises an insulating material supporting the electrode system and other components. Typically, plastics such as vinyl polymers, polyimides, polyesters, and styrenes provide the electrical and structural properties which are required. Further, because the test strip is preferably mass producible from rolls of material, it is desirable that the material properties be appropriate to have sufficient flexibility for roll processing, while also giving a useful stiffness to the finished strip. The base substrate can be selected as a flexible polymeric material such as polyester, especially high temperature polyester materials; polyethylene naphthalate (PEN); and polyimide, or mixtures of two or more of these. Polyimides are available commercially, for example under the trade name Kapton®, from E.I. duPont de Nemours and Company of Wilmington, Del. (duPont). A particularly preferred base substrate material is MELINEX® 329 available from duPont.

Electrodes

Type.

The invention relates to an “electrochemical sensor”, which is a device configured to detect the presence of, and/or measure the concentration of, an analyte by way of electrochemical oxidation and reduction reactions within the sensor. These reactions are transduced to an electrical signal that can be correlated to an amount or concentration of the analyte. The test strip therefore includes an electrode system 26 comprising a set of measuring electrodes, e.g., at least a working electrode and a counter electrode, within the sample-receiving chamber. The sample-receiving chamber is configured such that sample fluid entering the chamber is placed in electrolytic contact with both the working electrode and the counter electrode. This allows electrical current to flow between the measuring electrodes to effect the electrooxidation or electroreduction of the analyte.

In the context of the present invention, a “working electrode” is an electrode at which analyte is electrooxidized or electroreduced with or without the agency of a redox mediator. The term “counter electrode” refers herein to an electrode that is paired with the working electrode and through which passes an electrochemical current equal in magnitude and opposite in sign to the current passed through the working electrode. The term “counter electrode” is meant to include counter electrodes which also function as reference electrodes (i.e., counter/reference electrodes).

Electrode Material.

The working and counter electrodes, and the remaining portions of the electrode system, may be formed from a variety of materials, as known in the art. The electrodes should have a relatively low electrical resistance and should be electrochemically inert over the operating range of the test strip. Suitable conductors for the working electrode include gold, palladium, platinum, carbon, titanium, ruthenium dioxide, and indium tin oxide, and iridium, as well as others. The counter electrode may be made of the same or different materials, e.g., silver/silver chloride. In a preferred embodiment, the working and counter electrodes are both gold electrodes.

Electrode Application.

The electrodes may be applied to the base substrate in any fashion that yields electrodes of adequate conductivity and integrity. Exemplary processes are well known in the art, and include, for example, sputtering, printing, etc. In a preferred embodiment, gold electrodes are provided by coating the base substrate and then removing selected portions of the coating to yield the electrode system. A preferred removal method is laser ablation, and more preferably broad field laser ablation.

Laser ablative techniques typically include ablating a single metallic layer or a multi-layer composition that includes an insulating material and a conductive material, e.g., a metallic-laminate of a metal layer coated on or laminated to an insulating material (discussed below). The metallic layer may contain pure metals, alloys, oxides, or other materials, which are metallic conductors. Examples of metals or metallic-like conductors include: aluminum, carbon (such as graphite), cobalt, copper, gallium, gold, indium, iridium, iron, lead, magnesium, mercury (as an amalgam), nickel, niobium, osmium, palladium, platinum, rhenium, rhodium, selenium, silicon (such as highly doped polycrystalline silicon), silver, tantalum, tin, titanium, tungsten, uranium, vanadium, zinc, zirconium, mixtures thereof, and alloys or solid solutions of these materials. Preferably, the materials are selected to be essentially unreactive to biological systems; such materials include: gold, platinum, palladium, iridium, silver, or alloys of these metals or indium tin oxide. The metallic layer may be any desired thickness. In a preferred embodiment, the thickness is about 50 nm.

Configuration.

The electrode system may have a variety of configurations suited to the operation of the test strip and meter. For any embodiment, the working and counter electrodes preferably are positioned and dimensioned to minimize the volume of sample fluid required to cover them. It is also preferable that the electrodes be configured to maintain a current flux of sufficient magnitude as to be measurable using a relatively inexpensive hand-held meter.

By way of further example, a preferred embodiment includes a counter electrode which extends around both sides of the working electrode. The counter electrode therefore has two elements, one in front of the working electrode and the other behind the working electrode, as the sample fluid enters the sample-receiving chamber. More specifically, the counter electrode includes elements 40 and 42 which extend across the sample-receiving chamber. Each of these elements is about 250 μm wide. The working electrode element 44 has a width of about 250 μm, and is spaced from each of the two counter electrode elements by about 255 μm. It will be appreciated that this is only one of a number of configurations for the measuring electrodes.

The traces 30 and the contact pads 32 may be provided in a variety of fashions consistent with their intended function relative to the test strip. These components of the electrode system are preferably composed of the same material as the electrodes, and are preferably applied to the base substrate in the same manner and simultaneously with the application of the electrodes. In a preferred embodiment, the traces and contact pads are gold, and are formed by laser ablation, particularly as described in U.S. patent application Ser. No. 10/601,144, filed Jun. 20, 2003, entitled, Method of Making a Biosensor, the disclosure of which is hereby incorporated by reference. However, alternate materials and methods of application may be employed.

Chemistry

Reagent Composition.

The test strip includes a chemical reagent within the sample-receiving chamber for reacting with the test analyte to produce the electrochemical signal that represents the presence of the analyte in the sample fluid. The reagent layer can include a variety of active components selected to determine the presence and/or concentration of various analytes. The test chemistry is therefore selected in respect to the analyte to be assessed. As is well known in the art, there are numerous chemistries available for use with each of various analytes. For example, in one preferred embodiment, the test strip of the present invention can include one or more enzymes, co-enzymes, and co-factors, which can be selected to determine the presence of glucose in blood. The selection of an appropriate chemistry is therefore well within the skill in the art, and further description herein is not required in order to enable one to make and use the test strips with various analytes.

Adjuvants.

In conventional fashion, the reagent chemistry may include a variety of adjuvants to enhance the reagent properties or characteristics. For example, the chemistry may include materials to facilitate the placement of the reagent composition onto the test strip and to improve its adherence to the strip, or for increasing the rate of hydration of the reagent composition by the sample fluid. Additionally, the reagent layer can include components selected to enhance the physical properties of the resulting dried reagent layer, and the uptake of a liquid test sample for analysis. Examples of adjuvant materials to be used with the reagent composition include thickeners, viscosity modulators, film formers, stabilizers, buffers, detergents, gelling agents, fillers, film openers, coloring agents, and agents endowing thixotropy.

In a preferred embodiment of the test sample, the majority of the chamber is hollow before use. In the very small sample chamber of the test strips according to the present invention, it is preferable that the reagent layer be thin and uniform. Since the sample-receiving chamber is very small, less than about 1 μl, the depth or vertical height of the chamber is small. Consequently, the reagent layer should not occupy the majority of the internal cavity of the chamber. The reagent layer should be sufficiently thin to leave ample space for the test sample in the chamber. Further, the liquid test sample will hydrate or dissolve the thin reagent layer more quickly. As discussed in the above reaction scheme, the mediator and mediator redox products diffuse through and within the reagent layer/gradient to the electrodes. The reactive components and intermediates will have a short distance to diffuse through a thin reagent, therefore, diffusion to the electrodes will occur in less time. Additionally, the capture efficiency of mediator redox products at an electrode will be greater for a thin layer of enzyme than a thick layer.

Conversely, a thick reagent layer will take more time for the liquid test sample to hydrate or dissolve, and a thick reagent layer will increase the time that it takes for the mediator/mediator redox products to approach the electrodes. This can delay the time to determine the analyte concentration and introduce errors into the determination.

It is preferred that the reagent layer have a uniform thickness. Thickness inhomogeneity can lead to variability in determining the analyte concentration. In a preferred embodiment, the reagent layer has a uniform thickness throughout the entire sample receiving chamber. In this preferred embodiment, the reagent layer is not thicker around the perimeter of the sample receiving chamber adjacent the vertical side walls that define the chamber than in the central portion of the chamber. Consequently, the reagent layer does not exhibit a meniscus profile.

The reagent composition is formulated as a viscous solution that can be deposited in a thin, uniform layer on the base layer. The reagent composition includes thickeners and thixotropic agents to enhance the physical properties of the reagent layer. The thickeners are selected to provide a thick, liquid matrix having the remaining components homogeneously dispersed therein. The thickening and thixotropic agents also inhibit the liquid or semi-paste material from running or spreading over the surface of the base layer after it has been deposited and before it dries. After the reagent composition is deposited, it quickly dries to a readily hydratable matrix.

The reagent composition is provided to dry rapidly either with air drying or heat drying. After drying, the deposited reagent layer exhibits a thickness of between about 1 micron and about 20 microns. More preferably, the dried reagent layer exhibits a thickness of between about 2 microns and about 6 microns.

The reagent composition can be deposited on the test strip surface using a variety of coating methods including slot-die coating, curtain coating, hot melt coating, rotary screen coating, doctor blade or air knife coating, Meyer bar coating, and reverse roll coating techniques. These techniques are known to those skilled in the art. Preferably, the reagent layer is deposited on the flexible web as a wet composition at a thickness of between about 40 μm and about 100 μm. More preferably, the reagent composition is deposited as a wet composition at a thickness of between about 60 μm and about 80 μm. The composition may be applied as a uniformly thin layer of a reagent directly on top of the measuring electrodes and along the length of a web of multiple test strips, as a continuous narrow band. In preferred embodiments, the narrow band has a width of between about 7 mm and 8 mm and a dry thickness of between about 3 um and about 20 um. The composition may also be applied onto other electrodes that may reside in the sample-receiving chamber, depending on the desired functionality of such extraneous electrodes.

Spacing Layer

Configuration.

The test strip includes a spacing layer 14 which overlies the base substrate and which in part defines the sample-receiving chamber. In particular, the spacing layer 14 includes a void portion 22 substantially defining the height and the perimeter of the sample-receiving chamber 24. The void portion 22 is conveniently placed to have an edge opening whereby the sample fluid is contacted with the edge opening to enter into the sample-receiving chamber. The edge opening preferably is located at the end of the test strip, although it will be appreciated that placement on a side edge is also useful.

Materials.

The spacing layer 14 may be made of any material useful for fabrication with the test strip. Because the spacing layer partially defines the height of the sample-receiving chamber, the material should have sufficient strength at thicknesses appropriate to the desired height of the chamber. Another function of the spacing layer is to protect the electrode traces that extend along the upper surface of base substrate 12. The material should also be readily attached to the base substrate and the cover materials, either by heat-sensitive or pressure-sensitive adhesives, or other means, such as heat or laser welding. Examples of suitable materials include a 100 μm PET, or PEN foil coated or combined with adhesives such as ARCare 90132 from Adhesives Research Inc.

Covering Layer

Configuration.

A covering layer 16 is received over and attached to the spacing layer 14. One function of the covering layer is to form the top surface of the sample-receiving chamber. Another function is the provision of a hydrophilic surface to aid in acquisition of the test sample. In addition, the covering layer 16 preferably defines a vent opening 34 that allows air to escape from the interior of the chamber as the sample fluid enters and moves into the sample-receiving chamber.

The covering layer can be formed as a unitary piece with slot 34′ formed as a recess on the underside thereof, as shown in FIG. 1B. For mass production purposes, slot 34′ would be substantially straight as shown and extend across the entire width of the test strip, such that air would vent from the sample receiving chamber 24 to the vent openings formed on opposite lateral sides of the test strip. However, the slot could comprise a groove or recess that only extends from the chamber 24 to one side of the test strip, although such configuration is not preferred for mass production purposes.

Another alternate embodiment is shown in FIG. 1C, in which chamber cover 20 “overlaps” body cover 18. In this arrangement, a small end portion 37 of cover layer 20 is bent upwardly and extends across the edge of body cover 18. A slot 34″ is thereby formed having roughly a triangular shaped cross section as can be seen at the edges of the strip, at which there are triangular shaped openings that allow air to escape. In this “overlap” arrangement, the precise placement of the chamber cover 20 with respect to body cover 18 along the lengthwise direction of the strip is not critically important. That is, the amount of chamber covering material overlapping body cover 18 can vary without affecting the dimensions or placement of the slot. This has advantages in manufacturing, as will become apparent with reference to the discussion below.

Preferably, body cover 18 and chamber cover 20 comprise two separate members for ease in fabrication and in forming the vent opening. Body cover 18 and chamber cover 20 are both disposed in substantially the same horizontal plane. The chamber cover 20 substantially covers the void portion 22 of the spacing layer, and forms the top of the sample-receiving chamber. The chamber cover preferably includes a hydrophilic coating or treatment 21 on its underside, as described in more detail below. The body cover and the chamber cover are positioned end to end in the lengthwise direction along the test strip and include slot 34 therebetween as shown in FIG. 1A. The slot is located adjacent the interior end of the void portion 22 of the spacing layer, and in the preferred embodiment in FIG. 1A, forms a small gap that spaces chamber cover 20 from body cover 18. The gap constitutes the vent opening 34 in communication with the sample-receiving chamber. Slot 34 is substantially straight and extends across the width of test strip 10. Slot 34 is oriented substantially perpendicular to the longitudinal or lengthwise axis of test strip 10. Sample fluid entering the sample-receiving chamber will expel air through the vent opening defined by slot 34. If the slot be formed as a gap, some or most of the air expelled will exit from the top of the test strip.

The slot is located at a position relative to the sample-receiving chamber that is interior of the location of the electrode system 26. Sample fluid entering the sample-receiving chamber will progress as far as the vent opening, but no further. When viewed from the top, the slot provides a visual indication of a “fill-line,” as described herein. The placement of the vent opening therefore assures that sufficient sample fluid can be received to fully cover the electrode system. At the same time, the placement of the vent opening will inhibit continued wicking of the sample fluid beyond the region of the electrode system.

The formation of the slot and vent opening by the spacing of the body cover and the chamber cover is further advantageous because it avoids the need to otherwise form an aperture in the covering layer or base layer. In the prior art, it has been an approach to form the vent opening by punching a hole in either the top or bottom film forming the sample-receiving chamber, which presents fabrication issues because of the need to precisely locate the hole relative to the sample-receiving chamber. While this approach is also suitable for a test strip, the preferred design described herein avoids the need to align the vent opening laterally relative to the test strip. Further, the present design is well suited to mass production of the test strips by roll processing techniques, as described hereafter.

At the same time, the vent construction may be made in a manner to inhibit the wicking of sample fluid laterally along the slot beyond the middle area that overlies the sample receiving chamber 24. For example, the body cover is preferably secured to the spacing layer by means of an adhesive 46, as shown in FIG. 3. The use of a hydrophobic adhesive will inhibit blood, interstitial fluid, and other aqueous liquids from moving along the laterally-extending slot by capillary action. The entire body cover, or portions adjacent to the vent opening, may also be hydrophobic to inhibit wicking. Materials and methods for providing hydrophobic properties for a surface of a material are well known in the art. The chamber cover may be secured to the spacing layer by the same or different adhesive than adhesive 46, as explained below.

Adhesive 49 secures the spacing layer to the base substrate 12. Adhesive 46, as well as adhesive 49 and the material for spacing layer 14, are all formed of substantially hydrophobic material in the illustrated embodiment. As such, the vertical walls of the capillary chamber formed in strip 10 are hydrophobic. By contrast, the floor of the chamber is covered with a hydrophilic reagent and the underside of layer 20 is coated with a hydrophilic coating 21 (FIG. 2). In other words, the horizontal surfaces in the capillary are hydrophilic while the vertical surfaces are hydrophobic. This has been found to promote good wicking of the sample into the capillary chamber, yet prevents unwanted migration of the sample laterally from the chamber, e.g., between the spacer layer and the base substrate.

Materials.

The body cover and chamber cover may be made of any materials useful for fabrication with the test strip. The materials for the body cover and the chamber cover may be the same or different. The materials should be readily attached to the spacing layer, either by heat-sensitive or pressure-sensitive adhesives, or other means such as heat or laser welding. Examples of suitable materials for both the chamber cover and body cover include approximately 127 μm thick foil of PET. The chamber cover preferably includes a hydrophilic layer 21 as disclosed in WO 02/085185, ARFlow® 90191 from Adhesives Research Inc.

The covering layer 16 may also be used to facilitate viewing of the sample fluid as it enters the sample-receiving chamber. This is accomplished by providing a contrast in color or shading between the chamber and the surrounding area. For example, in one approach the portion of the spacing layer 14 that surrounds void 22 is provided with a color that contrasts with the color of the bottom of the sample-receiving chamber, e.g., the color of the chemical reagent layer positioned at the bottom of the chamber. This contrasting color may be provided, for example, by the application of an ink or other coloring agent to the portions of the spacing layer adjacent the sample-receiving chamber. A colored section 23 of layer 14 is pictured in FIG. 2. The chamber cover 20 is then provided as a transparent or translucent material that allows the user to view the chamber and the adjacent spacing layer. As sample fluid enters from the edge of the test strip, the user is able to observe its progress as it moves by capillary action toward the vent opening. This type of feature is further described in U.S. Pat. No. 5,997,817, issued to Crismore et al. on Dec. 7, 1999, and is hereby incorporated by reference.

Capillary

The sample-receiving chamber formed by the base substrate, spacing layer and chamber cover essentially comprises several sections into which the sample fluid will travel. A first, entry section 48 extends from the edge opening to the area of the measuring electrode system. A second, test section 50 extends through the area of the electrode system. A third section 52 extends from the measuring electrode system to the vent opening. It will be appreciated that the testing of the sample fluid occurs in the area of the electrode system in the test section. However, the sample fluid will also fill the other sections of the chamber in the course of filling the test strip.

Dimensions.

The height and width of the sample-receiving chamber are selected based upon a variety of considerations, including the fluid being tested and the analyte at issue. For example, the chamber dimensions are preferably sized to promote capillary flow of the test fluid into the chamber. Preferred chamber heights for use with blood, for example, are from about 50 μm to about 200 μm, and most preferably from 120 to 180 μm. In a preferred embodiment, the chamber height is about 150 μm. The width of the chamber may similarly be selected to match a desired sample fluid and analyte. For example, the chamber should be sufficiently wide to expose a desired amount of the working and counter electrodes, and should be narrow enough to avoid the requirement of an undue amount of sample fluid for testing. The width of the sample-receiving chamber and the width of the working electrode define the area of the working electrode. The area represents a further design consideration as it relates to signal amplitude and instrumentation design.

Volume.

The sample-receiving chamber is preferably provided as having a minimal volume, in order to reduce the amount of sample fluid needed for conducting a test. The overall sample-receiving chamber, including all of the three sections extending from the edge opening to the vent opening, has a total volume that can be considered to be a factor of the area of the chamber from the edge to the vent, and the height of the chamber from the base substrate to the chamber cover 20. However, the “net chamber volume” comprises the volume of sample fluid required to fill this space. The net chamber volume of the sample-receiving chamber will be the equivalent of the total chamber volume less the volume occupied by the electrodes, the reagent, and perhaps other items such as a sorbent material, if included.

As previously indicated, the volume of the overall sample-receiving chamber is comprised of the volumes attributable to the three sections of the chamber. Each of the sections is generally sized to be as small as practical for the operation of the test strip. However, there are considerations, and possibly other functions, that will impact on the size of each section.

The chamber volumes are a factor of both height and area. The height is a result of the thickness of the spacing layer and the thickness of the adhesives used to secure the spacing layer to the other layers. For example, the base substrate and the chamber cover are attached to opposite sides of the spacing layer. One method of attachment is the heat or laser sealing of the materials. It is preferred, however, to attach these layers by the use of suitable adhesives, such as heat-sensitive or pressure-sensitive adhesives. In this approach, the height of the sample-receiving chamber, i.e., the distance between the facing surfaces of the bottom substrate and the chamber cover, will be impacted by the thickness of the adhesive layers. As shown in FIG. 3, chamber 24 is bounded on its bottom side by reagent layer 33 and its top side by coating 21 of chamber cover 20. However, adhesive layers 46 and 49 as well as spacing layer 14 define the total height of chamber 24.

Further, in a preferred embodiment, the reagent layer 33 extends between base substrate 12 and spacing layer 14 and indeed extends the entire width of the test strip, as described below. The height of the chamber may therefore also be increased due to the presence of the reagent layer underlying the spacing layer. In this embodiment, and if adhesive is employed, it has been found that the adhesive may combine with the test reagent, at least to an extent that causes the adhesive to fill somewhat into and around the reagent. The heights of the reagent and adhesive layers therefore are not necessarily additive in the final test strip. Rather, the height of the resulting space between the base substrate and the spacing layer is somewhat less than the combination of the heights of the separate reagent and adhesive layers prior to lamination.

It has also been found that the combination of the adhesive and the reagent advantageously helps to create a seal along the edge of the sample-receiving chamber. This inhibits sample fluid from wicking into the reagent material present in the space between the base substrate and the spacing layer in the time frame necessary for performing a test.

The first entry section is available to receive the sample fluid and direct it to the measuring electrodes. This section can be quite small in size, and may comprise only a short segment of the chamber. The length of this section is preferably less than 1200 μm.

The second testing section includes the test or measuring electrodes, and is also sized to require a minimal volume of sample fluid. A primary factor controlling the size of this second section will be the type, number, size, signal strength, and configuration of the measuring electrodes. The length of this section is preferably about 1260 μm. A preferred volume is about 0.265 μL, based on a capillary height of 0.15 mm, and a capillary width of 1.4 mm.

The sample fluid moves past the measuring electrodes and into the third section. This provides assurance, and preferably allows for specific confirmation, that the measuring electrodes are properly wetted. This confirmation may be by visual observation by the user, or by automatic detecting means. For example, dose sufficiency electrodes may be placed in this section to detect when the sample fluid has progressed into this section to a point that the wetting of the measuring electrodes is assured. This can be used as a trigger for initiating the application of the potential to the electrodes. The length of this section is preferably 50 to 500 μm, and more preferably 255 to 400 μm. The volume is preferably 0.01 to 0.1 μL, and more preferably 0.05 to 0.08 μL.

In a preferred embodiment, the overall net chamber volume of the sample-receiving chamber is less than about 1 μL, and is more preferably less than about 0.5 μl. Desirable ranges for the net chamber volume of the sample-receiving chamber include volumes from about 0.15 to about 1.4 μL, more preferably from about 0.4 to about 0.7 μl.

Sorbent.

The sample chamber may be otherwise empty, which is preferred, or may alternatively include a sorbent material. Suitable sorbent materials include polyester, nylon, cellulose, and cellulose derivatives such as nitrocellulose. A sorbent material could be included to facilitate the uptake of the sample fluid by assisting in wicking the fluid into the chamber. The use of a sorbent material would also serve to further reduce the void volume of the sample-receiving chamber for reception of the sample fluid.

Fill Method.

The preferred method of filling the sample chamber is by capillary action. In addition, the filling of the test strip can be augmented by other means, such as applying a pressure on the sample fluid to push it into the sample chamber, and/or creating a vacuum on the sample chamber to pull the sample fluid into the chamber.

Hydrophilic Coating.

For purposes of capillary filling of the sample-receiving chamber, various approaches are available to facilitate the movement of the sample fluid into the chamber. For example, any or all of the surfaces defining the chamber may be selected or treated to improve hydrophilicity. Such treatment may comprise the use of known hydrophilic materials, application of a hydrophilic material onto the surface, or treatment of the surfaces to increase hydrophilicity, as described below. In addition, the reagent composition may be formulated to be readily hydrated and to encourage filling of the sample-receiving chamber. As previously indicated, a sorbent may also be used.

Testing for Analyte

The electrochemical sensor is operated by applying a suitable potential or series of potentials across the working and counter electrodes, and across the dose sufficiency electrodes. When a mediator is used, the magnitude of the required potential across the working and counter electrodes will be dependent on the redox mediator. Moreover, the potential at the electrode where the analyte is electrolyzed is typically large enough to drive the electrochemical reaction to or near completion, but the magnitude of the potential is preferably not large enough to induce significant electrochemical reaction of interferants. For glucose, for example, an applied potential difference typically is between about +100 mV and about +550 mV when using a DC potential. When using AC potentials these can be typically be 5 to 100 mV RMS.

A potential may be applied before or after the sample begins to enter the sample-receiving chamber. However, a potential is preferably applied after the sample has entered the chamber, and more preferably after it has been determined that there is a sufficient amount of sample in the sample-receiving chamber for conducting a test. The timing of the application of a potential may be triggered in a variety of fashions, including visual observation by the user, a time delay following sampling of the fluid to the test strip, or upon electrical or other automated detection of a sufficient amount of sample fluid in the chamber. The visual and electrical alternatives also may act as redundant failsafes to assure proper operation of the device. Preferably, the test strip and system utilize separate detecting means, such as dose sufficiency electrodes, for determining when the fluid sample has sufficiently filled the chamber.

When a potential is applied and the sample fluid is in the sample-receiving chamber, an electrical current will flow between the working electrode and the counter electrode. The current can be a result of the electrolysis of the analyte in the sample fluid when a potential of sufficient magnitude is applied. In this case electrochemical reaction occurs via the redox mediator, generally as previously described. In the case where small amplitude potential is applied, particularly in the case of AC potentials, the current is produced not necessarily by electrolysis, but by ionic motion and response of the dielectric in the sample chamber. Those skilled in the art will recognize that there are many different reaction mechanisms that will achieve the same result.

Control Solution

A test may be applied to the test strip after dosing to confirm that a control solution, and even that the correct control solution, has been administered. The control solutions aid the user in confirming that the entire system is functioning within design specifications, and that the test strips have not been stored improperly or otherwise mistreated. Acceptable strips will recover values within specified tolerance ranges for the particular strip lot being tested. The tolerance ranges in question will be published for each strip lot on the container label.

Method of Making Strip

In a preferred embodiment, the sensor comprises a multi-layered, laminate test strip 10. As previously described, the laminate includes a base substrate 12, a spacing layer 14, and a covering layer 16. These components may be assembled in various ways. For example, the components may be assembled by use of adhesives, heat sealing, laser welding (as is described in more detail below), and a variety of other suitable techniques appropriate for securing the adjacent materials. The test strips are preferably assembled in a large number on a single sheet or web, and the strips are thereafter separated for storage and use.

The laminate test strip may be assembled sequentially by successively laying down one layer at a time. Alternatively, the test strip can be prepared by assembling and processing individual components or layers, which are then laminated together to provide the functional test strip. In one preferred form, two or more basic components of the test strip are prepared simultaneously. Then in one or a series of assembly or laminating steps, the basic components are combined to produce the test strip, which may or may not require further processing. In a preferred embodiment, the test strip is assembled from three basic components: a metallized substrate preferably with a reagent layer coated on metallic electrodes defined on the substrate, a spacing layer having a cavity preformed therein, and one or more top or cover layers.

With such small dimensions for the sample-receiving chamber, the characteristics of the reagent layer can have a significant impact on the operation of the test strip, particularly in view of hydration and mixing characteristics. The reproducibility of the quantity, location, thickness and other properties of the reagent layer is therefore important. It is therefore desirable for the composition to include materials which specifically enhance the physical characteristics, such as the uniformity and flatness, of the applied layer.

In one particular aspect, the test strip includes a unique manner of incorporating the reagent. The reagent is placed in the sample-receiving chamber at least on the working electrode, and preferably also on the counter electrode. The reagent may be applied to the test strip in a variety of fashions as is well understood in the art. In a preferred embodiment, the reagent composition is applied as a thin coating over the electrodes supported on the base substrate.

More particularly, the reagent is placed onto the base substrate in a manner that positions the reagent composition between the base substrate and the spacing layer. This manner of application helps to make the reagent layer more flat and uniform in thickness. In contrast, a procedure of the prior art has been to first prepare the reaction well or cavity, and to then fill the reagent into the well. However, this can result in a more uneven reagent layer due to phenomena such as the formation of a meniscus at the perimeter of the well. This in turn can cause the reagent to have a different thickness adjacent to the side walls of the reaction well than in the interior portion, which can cause inconsistency in the filling of the chamber, prolonged dissolution intervals, and inconsistent mixing of the reagent with the sample fluid, and the ultimate test results. By placing the reagent onto the base substrate before the spacing layer is added, there is no meniscus effect to disrupt the even layering of the reagent as it dries on the base substrate. In addition, this method of application facilitates the mass production of the test strips.

Referring to the drawings, the test strip 10 is shown as including a reagent layer 33 that extends between the bottom substrate 12 and the spacing layer 14. More particularly, the reagent forms a layer 33 which covers both the top surface of the bottom substrate 12 and the electrodes 28. The reagent covers at least the working electrode, and preferably also the counter electrode. In the most preferred embodiment, the reagent layer extends the full width of the test strip. The reagent layer also preferably extends from the end edge to the dose sufficiency electrodes, and most preferably to the vent opening. The reagent layer thus extends under the spacing layer and is sandwiched between the spacing layer and the base substrate.

The reagent composition is applied to the bottom or base substrate in any suitable fashion that provides a desired and uniform layer which will ultimately extend under the spacing layer. The reagent is preferably applied in a continuous coating directly onto the bottom substrate, and onto the electrodes received thereon. As described hereafter, the reagent composition is most preferably applied in the course of producing a large quantity of test strips on a webbing of material. In this manner, the reagent may be applied in the way of a continuous stripe of material that extends over a substrate roll that is later separated into individual test strips. The reagent composition is allowed to dry or otherwise set up and the spacing layer is applied thereover.

In a related aspect, a preferred manner of securing the spacing layer to the bottom substrate is the use of an adhesive. In addition to securing the layers together, it has been found that the adhesive will sufficiently engage with the reagent composition as to help to seal the space between the bottom substrate and the spacing layer. The adhesives preferably placed on the spacing layer, which is laminated onto the base substrate. The adhesive thereby contacts the portion of the reagent which extends under the spacing layer.

Although the spacing layer of the illustrated embodiment is formed from Melinex® material with adhesives on both sides thereof, it is also possible to form spacing layer 14 as a continuous adhesive material, such as a double-sided tape. For example, a 5 to 6 millimeter thick ARCare Adhesive could be used in lieu of spacing layer 14.

In a further aspect, a preferred embodiment is described in which the analyte is glucose. In the case of glucose, the active components of the reagent composition will typically include an oxidoreductase, such as an enzyme for glucose; optionally a co-enzyme or co-factor; and a redox mediator. These components are typically dissolved or suspended in a matrix. The liquid test sample hydrates or dissolves the matrix, and the analyte diffuses through the matrix to react with one or more of the active components. Typically, the enzyme oxidizes the glucose in the test sample to gluconolactone and/or gluconic acid. The mediator, in turn, reacts with or oxidizes the reduced enzyme, and consequently the mediator is reduced in the process. The reduced mediator can be detected at one of the electrodes on the test strip.

In a specific example of an oxidation/reduction reaction scheme useful for detecting glucose in human blood, a test sample containing glucose reacts with an enzyme such as Glucose-Di-Oxidoreductase (Gluc-Dor), and optionally a co-enzyme or cofactor such as pyrrolo-quinoline-quinone (PQQ), in the presence of a redox mediator. The mediator may include, for example, benzoquinone, transition metal complexes, e.g., potassium ferricyanide, osmium derivatives (e.g., osmium bipyridyl complexes such as described in WO 98/35225) and nitrosoanaline derivatives (see U.S. Pat. No. 5,286,362). This produces the oxidized form of the analyte, gluconolactone, and the reduced form of the redox mediator. The mediator thereafter shuttles the redox equivalent of mediator product, the reduced mediator, to the electrode surface by diffusion. There the mediator is oxidized quantitatively at a defined anodic potential, and the resulting current is related to the apparent glucose concentration.

A representation of the reaction sequences for this reaction system using a nitrosoaniline derivative is provided below in Equation 1.

As shown, the nitrosoaniline derivative, o-methoxy-[N,N-bis-(2-hydroxyethyl)]-p-nitrosoaniline, initially exists as a mixture of two isomers, or tautomers, in equilibrium with each other. Reaction of Gluc-Dor with glucose in the test sample yields gluconolactone and the reduced form of Gluc-Dor (Gluc-Dor.2H⁺). The reduced form of Gluc-Dor (Gluc-Dor.2H⁺) reacts rapidly with the nitrosoaniline derivative, which is reduced and which regenerates Gluc-Dor. The reduced nitrosoaniline derivative then undergoes hydrolysis to form quinonediimine (QD). In a second enzymatic, redox reaction, Gluc-Dor reacts with glucose to yield another molecule of Gluc-Dor.2H⁺ and gluconolactone. The Gluc-Dor.2H⁺ reacts with (is oxidized by) quinonediimine to regenerate Gluc-Dor, and produces a phenylene diamine derivative (PD). PD is then oxidized at the working electrode to produce a current related to glucose concentration. Additionally, at the counter electrode QD can be reduced to PD.

Adjuvants.

With such small dimensions for the sample-receiving chamber, the characteristics of the reagent layer can have a significant impact on the operation of the test strip, particularly in view of hydration and mixing characteristics. The control and reproducibility of the quantity, location, width, thickness, and other properties of the reagent layer become more important as the chamber volume decreases and test time diminishes. It is therefore desirable for the composition to include materials that specifically enhance the physical characteristics, such as the uniformity and flatness, of the applied layer. Additionally, the method of application can impact the physical characteristics, control, and reproducibility of the reagent layer.

The reagent composition can therefore also include a variety of adjuvants to enhance the reagent properties or characteristics. For example, the composition may include adjunct materials to facilitate the placement of the reagent composition onto the test strip and to improve its adherence to the strip. The composition can also include materials to increase its rate of hydration and/or increase its influence on the capillary action to fill the chamber with the test sample. Examples of adjunct materials to be used with the reagent composition include thickeners, viscosity modulators, film formers, stabilizers, buffers, detergents, gelling agents, fillers, film opening agents, coloring agents, and agents endowing thixotropy.

The adjuvant materials or components can impact the application, reproducibility and physical properties of the reagent layer. The adjunct materials can include one or more of the following:

Thickeners may include, for example, (1) starches, gums (e.g., pectin, guar gum, locust bean (carob seed) gum, konjac gum, xanthan gum, alginates, and agar), casein, gelatin, and phycocolloids; (2) cellulose and semi-synthetic cellulose derivatives (carboxymethyl-cellulose, methyl cellulose, hydroxymethylcellulose, hydroxyethylcellulose, methylhydroxyethylcellulose); (3) polyvinyl alcohol and carboxy-vinylates; and (4) bentonite, silicates, and colloidal silica. Preferred thickeners include a combination of a xanthan gum sold under the trade name Keltrol F by CP Kelco US, Inc., and carboxylmethyl cellulose sold under the trade name AQUALON® CMC 7F PH by Hercules Inc., Aqualon Division.

Film forming and thixotropic agents useful in the reagent composition include polymers and silica. Preferred thixotropic agents include silica sold under the trade name Kieselsäure Sipernate FK 320 DS by Degussa AG. Preferred film forming agents include polyvinylpyrrolidone, sold under the trademark polyvinylpyrrolidon Kollidon 25, by BASF, and polyvinyl propionate dispersion.

Stabilizers for the enzyme in the reagent can be selected from saccharides and mono- or di-fatty acid salts. Preferred stabilizers include trehalose sold under the trade name D-(+)-Trehalose dihydrate by Sigma Chemical Co. and sodium succinate.

Detergents can be selected from water-soluble soaps, as well as water-soluble synthetic surface-active compounds such as alkali, earth alkali or optionally substituted ammonium salts of higher fatty acids, e.g., oleic or stearic acid, mixtures of natural fatty acids, for example, from coconut or tallow oil, fatty sulphates, esters of sulphonic acids, salts of alkyl sulphonic acids taurine salts of fatty acids, fatty acid amides, and ester amides. Preferred detergents for the present invention include an ester amide, n-octanoyl-N-methylglucamide, sold under the trade name Mega-8 by Dojindo Molecular Technologies, Inc., and a fatty acid salt, N-methyl oleyl taurate sodium salt, sold under the trade name Geropon T77 by Rhodia HPCII (Home, Personal Care and Industrial Ingredients).

It should be understood that one or more of the specific additives above described can exhibit additional properties and consequently could be categorized in one or more of the classes above noted.

Mediator.

A mediator for use in the reagent composition can be selected as any chemical species (generally electroactive) which can participate in a reaction scheme involving an enzyme, an analyte, and optionally a cofactor, and reaction products thereof, to produce a detectable electroactive reaction product. Typically, participation of the mediator in the reaction involves a change in its oxidation state (e.g., a reduction), upon interaction with any one of the analyte, the enzyme, or a cofactor, or a species that is a reaction product of one of these (e.g., a cofactor reacted to a different oxidation state). A variety of mediators exhibit suitable electrochemical behavior. A mediator can preferably also be stable in its oxidized form, may optionally exhibit reversible redox electrochemistry, can preferably exhibit good solubility in aqueous solutions, and preferably reacts rapidly to produce an electroactive reaction product. Examples of suitable mediators include benzoquinone, meldola blue, other transition metal complexes, potassium ferricyanide, osmium derivatives (see WO 98/35225) and nitrosoanaline-based mediators (see U.S. Pat. No. 5,286,362). In a preferred embodiment, the reagent composition utilizes a nitrosoaniline-based chemistry.

Preferred mediators include N-(2-hydroxyethyl)-N′-p-nitrosophenyl-piperazine, N,N-bis-(2-hydroxyethyl)-p-nitrosoaniline, o-methoxy-[N,N-bis-(2-hydroxyethyl)]-p-nitrosoaniline, p-hydroxynitrosobenzene, N-methyl-N′-(4-nitrosophenyl)-piperazine, p-quinone dioxime, N,N-dimethyl-p-nitrosoaniline, N,N-diethyl-p-nitrosoaniline, N-(4-nitrosophenyl)-morpholine, N-benzyl-N-(5′-carboxypentyl)-p-nitrosoaniline, N,N-dimethyl-4-nitroso-1-naphthylamine, N,N,3-trimethyl-4-nitrosoaniline, N-(2-hydroxyethyl)-5-nitrosoindoline, N,N-bis-(2-hydroxyethyl)-3-chloro-4-nitrosoaniline, 2,4-dimethoxy-nitrosobenzene, N,N-bis-(2-methoxyethyl)-4-nitrosoaniline, 3-methoxy-4-nitrosophenol, N-(2-hydroxyethyl)-6-nitroso-1,2,3,4-tetrahydroquinoline, N,N-dimethyl-3-chloro-4-nitrosoaniline, N,N-bis-(2-hydroxyethyl)-3-fluoro-4-nitrosoaniline, N,N-bis-(2-hydroxyethyl)-3-methylthio-4-nitrosoaniline, N-(2-hydroxyethyl)-N-(2-(2-methoxyethoxy)-ethyl)-4-nitrosoaniline, N-(2-hydroxyethyl)-N-(3-methoxy-2-hydroxy-1-propyl)-4-nitrosoaniline, N-(2-hydroxyethyl)-N-(3-(2-hydroxyethoxy)-2-hydroxy-1-propyl)-4-nitrosoani line, N-(2-hydroxyethyl)-N-(2-(2-hydroxyethoxy)-ethyl)-4-nitrosoaniline. Particularly preferred mediators according to the present invention include N,N-bis-(2-hydroxyethyl)-p-nitrosoaniline, o-methoxy-[N,N-bis-(2-hydroxyethyl)]-p-nitrosoaniline, and N-(2-hydroxyethyl)-N-(2-(2-hydroxyethoxy)-ethyl)-4-nitrosoaniline.

An exemplary reagent composition is listed below in Table I. TABLE I Components Function Amount Abs. % solids w/w. Note. Keltrol F Thickener 11.60 g 0.24% Carboxy methylcellulose Thickener 27.24 g 0.57% Kieselsäure Sipernat 320 DS Film Opener 97.01 g 2.01% Polyvinylpyrrolidine PVP K25 Film Former 89.33 g 1.85% Propiofan Film Former 257.09 5.34% GlucDOR Apo-Enzyme 19.127 g  0.40% 0.673 MU/g pyrrolo-quinoline quinine Co-Factor 0.5329 g  0.01% (PQQ) Na-Succinate Stabilizer 23.23 g 0.48% Trehalose Stabilizer  23.6 g 40.49%  KH₂PO₄ Buffer 12.02 g 0.39% K₂HPO₄ × 3H₂O Buffer 43.43 g 0.90% Nitrosoaniline Mediator 41.26 g 0.86% Mega 8 Detergent 13.23 g 0.27% Geropon T77 Detergent 1.405 g 0.03% KOH 5N Adjust Buffer 36.47 g 0.76% Water total 4114.52 g  Sum 4817.80 g  Solids 14.6% Mixing.

The components of the reagent composition are admixed with water to provide a homogeneous, viscous suspension. The order of addition is not critical for the invention. A sufficient amount of the buffer solution is added to maintain the reagent composition at a pH of about 7. Typically the selected components are pre-mixed with water to provide a variety of stock solutions that can be combined to yield the final reagent composition. For example, a buffer solution can be prepared by combining the phosphate salts and, optionally, the sodium succinate. Other stock solutions include: the thickening agents, i.e., Keltrol F and the carboxymethyl cellulose; the surfactants, i.e., Geropon T77 and Mega 8; the enzyme and co-enzyme or cofactor; and the mediator.

The following provides an example of the preparation of a reagent composition. The reagent composition can be prepared by first preparing the following stock solutions: Buffer Solution pH 6.9 to 7.1 Amount (gm) H₂O 1214.62 KH₂PO₄ 18.27 K₂HPO₄ 43.43 Na succinate 23.23

Keltrol F Solution Amount (gm) H₂O 287.06 Buffer Solution 101.35 Keltrol F 11.60

Carboxymethylcellulose (CMC) Solution Amount (gm) H₂O 1334.76 Na CMC¹ 27.24 ¹Na CMC is a sodium salt of carboxymethyl cellulose sold by Hercules Inc., Aqualon Division

Silica Suspension Amount(gm) H₂O 722.99 Sipernat 320¹ ¹Kieselsäure Sipernat 320 DS (Silica) sold by Degussa AG.

Polyvinylpyrrolidone (PVP) Solution Amount (gm) Buffer Solution 226.03 Mega 8¹ 13.23 Geropon T77² 1.405 PVP³ 89.33 ¹Mega 8 is n-octanoyl-N-methylglucamide sold by Dojindo Molecular Technologies Inc. ²Geropon T77 is N-methyl oleyl taurate sodium salt sold by Rhodia HPCII. ³PVP is Polyvinylpyrrolidone K25 sold by BASF.

Trehalose Solution¹ Amount (gm) H₂O 36.4 Trehalose 23.6 ¹This trehalose solution is used only in preparing the “Enzyme Solution” listed below.

PQQ Solution Amount (gm) Buffer Solution 1^(st) 101.59 addition PQQ 0.533 Buffer Solution 2^(nd) 30.0 addition

Enzyme Solution Amount (gm) PQQ Solution 132.12 Gluc-Dor 19.13 (673 U/mg Ly) Trehalose Solution 58.75

Mediator Solution Amount (gm) Buffer Solution 782.27 Mediator 41.26 5 N KOH 36.47

The buffer solution, Keltrol F solution, CMC solution, and the Silica suspension were prepared a day before. These solutions can then be combined as listed below to prepare the reagent composition. Final Reagent Composition Thickener I 331.51 g (Keltrol F solution) Thickener II (CMC 1262.9 g Solution) PVP Solution 315.05 g Silica suspension  762.3 g Propiofan solution 257.09 g Mediator Solution 855.84 g Enzyme Solution 196.65 g 5N KOH as required to achieve final pH of 6.9 to 7.1 Water (bidistilled) 518.69 g For this reagent prior to coating, the final pH was 6.96 and did not need adjustment with 5N KOH solution. The measured viscosity was 111 mPas, which is in the correct range for coating of 105 to 115 mPas.

FIGS. 5 and 5A present a flow chart illustrating a preferred process 100 for preparing a test strip useful in accordance with the present invention. Process 100 begins in the central process line 101 at stage 102 with selection of a film material for the base layer or base substrate. In a preferred embodiment, the film is provided as a continuous roll having a width and length suitable for fabricating a large number of test strips. In subsequent finishing steps, the processed film can be subdivided to provide a single strip or web having a width that approximates the length of the test strip and includes a series of test strips, or can be die cut to provide individual test sensors.

From stage 102, the film proceeds to stage 104 where it is pretreated to receive a metal coating and coated with the metal in one continuous process. The pretreatment 164 (discussed below) can be used to clean or modify the surface to provide a uniform coating thickness and better adhesion of the subsequent metallized layer 166 (discussed below). The pretreatment can include subjecting the film to corona discharge or Argon plasma. Immediately after this pre-treatment, a uniform conductive coating is applied to the film as shown at 106. Alternatively, suitable substrates with metal coatings can be obtained commercially.

The metallic layer may contain pure metals, oxides, alloys, or other materials, which are metallic conductors. Examples of metals or metallic-like conductors include: aluminum, carbon (such as graphite), cobalt, copper, gallium, gold, indium, iridium, iron, lead, magnesium, mercury (as an amalgam), nickel, niobium, osmium, palladium, platinum, rhenium, rhodium, selenium, silicon (such as highly doped polycrystalline silicon), silver, tantalum, tin, titanium, tungsten, uranium, vanadium, zinc, zirconium, mixtures thereof, and alloys or solid solutions of these materials. Preferably, the materials are selected to be essentially unreactive to biological systems; such materials include: gold, platinum, palladium, iridium, or alloys of these metals. The metallic layer may be any desired thickness.

The conductive coating is preferably a metal layer that is applied by a variety of methods, including but not limited to sputtering, physical vapor deposition (PVD), plasma assisted vapor deposition (PAVD), chemical vapor deposition (CVD), electron beam physical vapor deposition (EBPVD), and/or metal-organic chemical vapor deposition (MOCVD). Vapor deposition is typically performed under vacuum. These techniques are well known in the art and can be used to selectively provide a uniformly thin coating of metal onto a substrate. The resulting metallized film can be inspected to ensure that the metal coating is uniform and free of material defects.

The roll of metallized film next encounters stage 108 where it is subdivided and/or sized to provide webs having a width that approximates the final length of an individual test strip. The slicing can be accomplished using fixed-knife slitting equipment well-known in the art.

A single web proceeds to stage 110 for patterning the electrodes, traces, and contacts or pads. At this stage, the electrodes, traces, and contact pads are formed by removing metal from the surface of the web strip. The excess metal can be removed using a variety of techniques well known in the art. At this stage, one or more indexing or registration marks can be formed either on a first edge proximate to the electrodes, the opposite second edge proximate to the electrode pad, on both edges or anywhere in between. The indexing marks, particularly those at an edge, can be used in subsequent operations to align layered components prefabricated in separate operations.

In a preferred method, the metal is laser ablated to eliminate undesired portions of the metal and leave the desired electrical components. In accordance with this method, selected areas are laser etched simultaneously, in a “broad field”, as opposed to using linear movement of a focused laser beam. This broad field laser ablation method provides a precise metal pattern rapidly and at reduced cost as compared to other approaches. Corona treatment of the patterned substrate is then conducted at stage 111.

The patterned web continues on to stage 112, where a reagent layer is deposited onto the electrodes. In a preferred embodiment, the reagent layer is deposited as a continuous elongate stripe extending adjacent or close to the first edge, and overlying the measuring electrodes formed on the patterned web. As previously noted, the reagent is consequently located across the full width of the test strip, including the area laterally outside of the sample-receiving chamber and between the base substrate and the spacing layer. Also as noted, this will facilitate the drying of the reagent without discontinuities, edge effects, or other variances that would detract from providing a thin, flat, uniform reagent layer within the sample-receiving chamber. The reagent includes a combination of components, and is formulated to dry rapidly with minimal or no running after deposition, typically by manipulating the thixotropy of the coated reagent film.

This stripe may be applied in any suitable fashion which provides the desired extent and uniformity of thickness, precision of the stripe edge, homogeneity, and the like. Preferred methods are capable of applying the desired coating at relatively high speed and high batch size. Suitable methods of application are well known in the art and therefore are not detailed herein.

Preparing the Spacing Layer

Referring now to process line 114, a process flow for preparing the spacing layer is illustrated. Beginning at stage 116, a material is selected to prepare a spacing layer for laminating on top of the reagent-coated web prepared at stage 112. The base film for the substrate can be selected from a variety of materials. The spacing layer material, similar to the base layer, can be provided as an elongate roll which can be conveniently processed rapidly and with high efficiency. Preferred materials include a polyester film sold under the trade name MELINEX® by DuPont. Other materials suitable for use in the present invention could include PEN. The spacing layer material has a thickness specifically selected to provide a desired chamber depth (or height) in each of the test strips when combined with the thicknesses of any joining layers that are used to laminate the spacer to the other strip components. In preferred embodiments, the spacing layer is selected to have a thickness between about 75 μm and about 150 μm, more preferably from about 100 μm to about 125 μm. As noted above, the spacing layer can be formed of a double-sided adhesive.

The spacing layer is preferably formed as a continuous film having a series of gaps that will align with the electrodes on the bottom substrate webbing. The manner of joining the spacing layer and bottom substrate will impact the method for preparing the spacing layer. For example, if the spacing layer is to be heat welded to the bottom substrate, then the spacing layer may simply be die cut to provide the appropriately spaced chamber gaps. However, a preferred method is the use of thin, non-interfering adhesives that join the adjacent layers. In accordance with this preferred method, a spacing layer is prepared for combination with the previously described substrate webbing as set forth hereafter.

The spacing layer film is prepared having the desired width for combination with the remainder of the test strip components. The spacing layer film may include an opaque portion, e.g., a section 23 of it is printed blue or another color for use in visualizing the sample-receiving chamber, as described elsewhere. The spacing layer film is laminated on the bottom side with a combination adhesive and release liner, and on the top side with a similar combination adhesive and liner.

At stage 118, two transfer adhesives are laminated to the spacing layer material: the first transfer adhesive is laminated to the top surface of the spacing layer, and the second transfer adhesive is laminated to the bottom surface of the spacing layer. Preferably, the transfer adhesives are the same adhesive; however, in alternative embodiments, the first and second transfer adhesives can be different from each other. In preferred embodiments, the transfer adhesives are selected from commonly used and known adhesives, including pressure sensitive adhesives. Preferred adhesives exhibit sufficient hydrophobicity to prevent or inhibit the test sample in the chamber from wicking out between the spacing layer and the reagent layer or base substrate. An example of a suitable sensitive adhesive is ARCare 90132 from Adhesives Research Inc. The adhesives are provided with a release liner to prevent premature adhesion of the spacing layer during processing. The release liners are disposed on the exterior surface of the first and second transfer adhesives, facing outward from the spacing layer material.

The spacing layer with the adhesive release liners on the top and bottom surfaces progresses to stage 120. At stage 120, the cavity which will form the sample-receiving chamber is punched in the spacing layer. In one embodiment, the cavity is punched using a “kiss cut” method. The kiss cut method cuts through the upper release liner, the upper adhesive, the spacing layer, and the lower adhesive, but not through the lower release liner. In subsequent operations, simply removing the lower release liner will then remove the punched out portions of the lower adhesive, the spacing layer, the upper adhesive, and the upper release liner from the punched spacing layer. In other embodiments, the cavity can be punched through with a hollow die. The hollow die completely punches or cuts through the spacing layer, the two adhesives, and the two release liners, with the punched out portion subsequently removed in the hollow die. The spacing or pitch between each cavity is determined and accurately controlled to allow accurate mating of the punched spacing layer over the electrodes using one or both of the indexing marks patterned in the reagent-coated web.

At stage 122, the lower release liner on the spacing layer is removed, taking with it the kiss cut portions and exposing the adhesive on the underside surface of the spacing layer. Proceeding on to stage 124 in process line 101, the spacing layer is laminated over the reagent-coated web using one or more of the indexing marks previously patterned on the web to correctly align each cavity formed in the punched spacing layer directly on top of an electrode set to provide a web-spacing layer laminate. At stage 126 in the central process line 101, the upper release liner covering the upper adhesive on the web-spacing layer laminate is removed in preparation for attaching the cover layer.

Laminating on the Cover Portions

At stage 128, a material for a body cover is introduced into the process. In preferred examples, the material is a flexible polymeric material and may be selected, for example, MELINEX 454 or MELINEX 339 from du Pont. The material for the body cover is sized to have a width sufficient to overlay at least a portion of the electrode traces in the sample-receiving chamber of the test strip.

Referring now to process line 130, beginning at stage 131, a film material is selected to provide a chamber cover over the cavity, reagent, and measuring electrodes on the web-spacing layer laminate. In preferred embodiments, the body cover material is provided as a clear poly(ethylene-terephthalate) (PET) or poly(ethylene-naphthalate) (PEN) film having a thickness between about 100 μm and about 200 μm. The coating may preferably include a release liner, which can be removed immediately prior to laminating over the web-spacing layer. The chamber cover is preferably made from a hydrophilic material or the bottom surface of the chamber cover may be treated or coated to make it hydrophilic as indicated at 134. At stage 138, the film material can be sized to a desired width sufficient to form the chamber cover to overlay the cavity and electrodes.

Proceeding to stage 140, the body cover from stage 128 and the chamber cover from stage 138 are laminated to the web-spacing layer laminate. In preferred embodiments, the body cover and chamber cover are simultaneously laminated with the web-spacing layer laminate. The body cover is positioned over a portion of the electrode traces proximate to the electrodes formed on the base substrate. The chamber cover is positioned over the cavity, reagent, and measuring electrodes on the web-spacing layer laminate. The body cover and chamber cover are separated by a gap to form a vent 34 at the interior end of the cavity formed in the test strip.

As described, the chamber cover is placed near the edge of the strip to overlie the cut out portion of the spacing layer, leaving the innermost portion of the cut out uncovered. As just described, this chamber cover preferably includes a hydrophilic underside to promote the wicking of fluid into the reagent chamber. The chamber cover is spaced slightly from the body cover to form a gap which thereby communicates with the sample-receiving chamber and serves as a vent opening for air to escape as fluid enters the chamber, as described above.

The opacity of the spacing layer and the transparency of the chamber cover cooperate to allow a user of the final test strip to better view the progress of a test. As constructed, the bottom substrate or reagent layer coated thereon is visible through the cut out in the spacing layer and through the transparent chamber cover. The bottom substrate and/or reagent has a light color, e.g., bright yellow, which contrasts with the opaque coloring of the spacing layer. Therefore, the progress of a fluid through the capillary channel can be easily monitored by the person using the test. Further, since the slot 34 is configured to be hydrophobic on the body cover side and hydrophilic on the chamber cover side, fluid will abruptly stop when it reaches the slot, thus presenting a sharply defined fill-line which in turn provides a clear indication to the user that sufficient fluid sample has been received into the chamber.

Separating the Test Strips

From stage 140, the finish processing steps for the fabrication of test strips are performed. At stage 141, a profile cut is made across the end of the web of test strips 10. Typically, the profile cut is made in two steps. First, the web is sheared by a cutting blade moving across the web, thereby forming a straight edge; then the web is die-cut to produce the desired profiled shape (a taper for the illustrated embodiment) of the dosing end 36 of the test strips.

At stage 142, any graphics or logos are printed on the test strips 10.

At stage 143, a decision is made whether to manufacture a single, die-cut test strip similar to the single test strip 10 above discussed. If so, then the multi-layered laminate from stage 143 proceeds to stage 144 to be die cut into single test strips.

Alternatively, the multi-layered laminate from stage 143 proceeds to stage 148, where it is kiss cut to define individual test strips and to perforate or weaken the boundaries between adjacent test strips on the ribbon. Additionally, at stage 149 the ends of the test strips are die cut along the laminated ribbon. One end of the web is cut to form the fluid receiving end of the test sensor with a Y-shaped opening leading into the cavity. The test strips may be divided into cards comprising a number, e.g., 25, of strips which are only fence cut and then folded to be stacked in a vial or dispenser.

Proceeding out of either stage 144 or 149, the processed strips or ribbon of strips are inspected and ultimately packaged for use by the consumer at stage 146 or 150, respectively.

FIGS. 6-16 illustrate in greater detail some of the components and/or process stages previously described with respect to FIGS. 5 and 5A. FIG. 6 illustrates a perspective view of one embodiment of a base film for use in forming the test strip. Base film 160 is preferably provided as a flexible film or web material that is rolled onto one or more rollers 162 with processes 164, 166 proceeding on the material between the rollers.

The pretreated upper surface of the film is metallized using a sputtering, PVD, CVD, EBPVD, MOCVD or another suitable process, illustrated by reference number 166 and described more fully above, to deposit a uniform coating of a metal or metal alloy. The processes can use a single or multiple target source for the metallic layer. The metallized film 168 can then be sectioned or subdivided into a plurality of metallized films, e.g., 170 a, 170 b, and 170 c, by cutting or slicing the film as illustrated by reference number 172. Each separated roll of the conductive, metallized film 170 can then be rolled upon a single core or upon a plurality of different cores as preferably desired.

The electrical components are formed from the conductive film, as shown in one embodiment in FIG. 7. The metallic surface of film 170 is treated to remove any metallic component that is not desired to form the electrodes, traces, contact pads, or other intended features. This process can be precisely controlled using laser ablation or other technology. The process provides a plurality of sets of electrodes 182, traces 184, and contact pads 186. The process can also provide a plurality of indexing or registration marks 176 along a first edge 178 and/or similar registration marks 177 along the opposite edge 180. As shown in FIG. 7, repeating features of the electrode pattern form registration markings 177. Preferably, each set of electrodes and/or contacts is associated with at least one index or registration mark, 176 and 177, respectively.

FIG. 8 illustrates a portion of a reagent-coated web 188. The reagent composition is deposited on the surface of the flexible web material. The reagent layer 190 is deposited using a variety of coating methods including curtain coating, hot melt coating, rotary screen coating, doctor blade or air knife coating, Meyer bar coating, and reverse roll coating techniques. Preferably, the reagent layer is deposited on the flexible web as a wet composition at a thickness of between about 50 μm and about 100 μm, more preferably, between about 60 μm and about 90 μm. Web 188 can be provided by coating a uniformly thin layer of reagent 190 directly on top of electrode sets 182 and along the length of web 188 as a continuous narrow band 192. In preferred embodiments, the narrow band 192 has a width of between about 5 mm and 9 mm and a dry thickness of between about 2 μm and about 10 μm. As depicted in FIG. 8, the reagent layer 190 is translucent.

FIG. 9 is an exploded view of a spacing layer assembly 194, which can be assembled in accordance with the present invention. Spacing layer assembly 194 comprises a spacing layer 196 preferably formed of a polymeric material. Spacing layer 196 includes a band or section 197 that is colored (corresponding to section 23, FIG. 2). In the manufacturing process, spacing layer 196 is provided in a roll 198 and is then overcoated with adhesives on top and bottom.

The top adhesive is provided in a roll 200 which further comprises a top or “tight” release liner 202, which is adapted to withstand further processing, an adhesive 204, and a lower or “easy” release liner 206. Preferred adhesives 204 for use in the present invention include a pressure-sensitive adhesive sold under the trade name ARCare 90132 by Adhesives Research Inc. During assembly, bottom release liner 206 is removed and the resulting adhesive 208 having the top release liner 202 still present is adhered to spacing layer 196 as indicated in the top of FIG. 9.

Similarly, the bottom adhesive is provided in a roll 210 which further comprises a top or “tight” release liner 212, which is adapted to withstand further processing, an adhesive 214, and a lower or “easy” release liner 216. Preferred adhesives 214 for use in the present invention include a pressure-sensitive adhesive sold under the trade name ARCare 90132 by Adhesives Research Inc. During assembly, bottom release liner 216 is removed and the resulting adhesive 218 having its top release liner 212 facing away from spacing layer 196 is adhered to spacing layer 196 as indicated in FIG. 9. It should be understood that adhesive 204 can be the same or different from adhesive 214.

FIG. 10 illustrates spacing layer 196 that has been die cut to form pre-capillaries 220 a, 220 b, 220 c, etc., and is ready to be laminated to a web of base substrate material 188 as described with reference to FIG. 8. Pre-capillaries 220 can be formed using a “kiss-cut” technique in which a die cuts through the top release liner 202, adhesive 204, spacing layer 196, and adhesive 214, but not release liner 212, which, as noted above, faces away from spacing layer 196. Release liner 212 is then removed along with portions of the top release liner 202, adhesive 204, spacing layer 196, and adhesive 214 that had been cut through. These portions that are cut through comprise “capillary trim,” i.e., a sandwich of layers shaped like pre-capillaries 220. This “trim” is removed along with release liner 212, leaving the cavities 220 devoid of any material. As release liner 212 is removed, it can be inspected to ensure that it always contains the capillary trim just described. The resulting series of cavities 220 are spaced from each other a desired distance selected to position each one of the channels of the series of channels 220 directly over a measuring electrode set in the test strip. The spacing layer 196 having its lower adhesive exposed can then be aligned with web 188 by means of indexing marks 176 and laminated thereto. Each capillary channel of the series of channels 220 overlays one set of measuring electrodes 182.

FIG. 11 illustrates an assembly 230 formed by the lamination of spacing layer 196 to web 188. In FIG. 11, the upper release liner 202 has been removed from the top adhesive 208, which makes assembly 230 ready for assembly of additional material thereto. As shown in FIG. 12, a web 240 of chamber covering layer material and a web 234 of body covering material are aligned over the exposed upper adhesive 208 of assembly 230 and are ready to be adhered thereto. As depicted in FIG. 12, chamber covering layer 240 is clear and includes a hydrophilic coating (see coating 21, FIG. 2) on at least the side that faces cavities 220. This facilitates wicking or transport of the liquid sample into the sample-receiving chamber and over the electrodes and reagent layer. Body cover 234 is opaque, is colored as shown, and is preferably hydrophobic. Covering layer 240 and body cover 234 can be provided on reels like those described above with reference to FIG. 9.

Preferably, chamber covering material 240 is slightly thinner than body covering material 234. After the chamber covering material 240 and body covering material 234 are laminated to the other layers (described below), the assembly is rewound to await the final processing steps. If body covering material 234 is thicker than chamber covering material 240, then body covering material 234 will absorb more of the pressure or force imparted to the web as it is rewound and stored. Thus, if any adhesive squeezes out of the web as it is rewound, the adhesive will squeeze out around the body covering material 234 and not the chamber covering material 240. Advantageously, the thinner chamber cover thus reduces the possibility of the adhesive squeezing out from under it during roll processing and entering the capillary zone where it could degrade or destroy the test strips ultimately produced. Additionally when assembly 260 (discussed below) is re-rolled onto a core, the pressure exerted on the chamber covering material 240 is less than that exerted on body covering material 234 which minimizes the possibility of damage during processing to the capillary chamber.

Assembly 260 shown in FIG. 13 is produced by laminating webs 234 and 240 to the assembly 230 shown in FIG. 12 and then trimming the end of the web to form dosing edge 250. Dosing edge 250 is preferably formed by a shear cut in which the cutting blade moves across the end of the web as indicated by arrow 252. By contrast, it is more difficult to use a die punching technique without damaging the capillaries. The shear cut along dosing edge 250 also cuts away a portion of the pre-capillaries 220 and defines the final volume of capillaries 222. Capillaries 222 preferably include a flared or Y-shaped opening as shown. Preferably, a gap 262 is formed between the chamber covering web and the body covering web and this gap will ultimately provide a vent opening in the individual test strips. In preferred embodiments, the gap has a width of between 1.0 mm and about 1.6 mm. As noted above, however, the gap could be replaced by using a unitary covering layer having a notch formed on its underside (FIG. 1B) or by having the chamber cover overlap the body cover or vice versa. (FIG. 1C).

With further reference to FIG. 13, assembly 260 is ready for further processing as indicated by dashed lines 262 and 264. In FIG. 14 there is shown the kiss-cut strip 276 having a plurality of individual test strips, e.g., 278 a, 278 b, and 278 c, detachably connected together. It can be observed that kiss-cut strip 276 has been trimmed or cut at its upper end along lines 262 in FIG. 13 to have a profile and/or configuration suitable to facilitate capturing a very small fluid sample in each of the series of capillary channels 222. In the illustrated embodiment, kiss-cut strip 276 has a flat working end 280 exposing the end of the sets of Y-cut capillary channels 222. The resulting configuration of second edge 282 can be provided to facilitate insertion of a single strip into a meter (not shown). For example, the second edge 282 can have a registration mark and/or tabs, cut slots, or other configurations designed to allow insertion of a single strip into the meter in only one direction. For example, with reference to FIG. 13, the edges 177 of contact pads 288 are spaced by a constant pitch, “P” as shown, and edges 177 can therefore be used as registration marks. As in other processing steps, the indexing or registration marks 176 and 177 on either the first edge and/or the second edge can be used to accurately “kiss cut” and trim the individual test strips from the laminated structure 260.

FIG. 15 is a perspective view of one embodiment of a punched cut test strip 290 formed by cutting through the dashed lines 264 shown in FIGS. 13 and 14. Strip 290 illustrated in FIG. 15 has been substantially described above as test strip 10. Strip 290 is provided as an individual test strip separate from any other test strip.

Flared Portion of Sample Receiving Chamber

As described above and in more detail in this section, embodiments incorporating the invention recited in the appended claims include a sample receiving chamber having a flared portion that terminates in a sample receiving opening. As one should appreciate, the capillary action that draws sample fluid into the capillary-sized sample receiving chamber is the result of adhesion of the fluid to the walls of the capillary channel as well as the surface tension of the fluid to be sampled. Adhesion of the fluid to the walls of the capillary channel results in a force acting on the fluid at its edges and results in a meniscus. The surface tension, or cohesion of the liquid molecules of the fluid, acts to hold the surface intact, so instead of the edges moving inward in the capillary, the entire liquid sample is pulled into the capillary. Capillary action occurs when the adhesion to the walls of the capillary channel is stronger than the cohesive forces between the liquid molecules in the bodily fluid sampled.

In a uniform capillary tube, the height to which capillary action will be able to lift liquid depends on the surface tension of the liquid and the weight of the liquid. By reducing the size of the capillary, the ratio of adhesion of the fluid to the surface of the capillary to the weight or mass of liquid to be drawn into the capillary is increased, thereby increasing the net force which pulls the fluid into the capillary. Consequently, capillaries that are smaller in size are able to draw liquid more quickly and to a greater extent as compared to larger capillaries. Thus, capillary channels are typically very small and are continually being designed smaller to lessen the amount of sample needed for testing.

However, the smaller the capillary entrance width, the more difficult it becomes to accurately apply (or “target”) a 0.05 μl or 1 μl sample volume to the capillary of the test strip. In the embodiments described below, the capillary channels are flared or “Y-shaped”; i.e., they narrow in a direction inwardly of the sample receiving opening. Advantageously, because the capillary channel narrows beyond the opening or entrance, the increased forces provided by the narrow and elongated part of the channel will draw fluid from the flared portion, which can also be referred to and thought of as a “pre-chamber.” Furthermore, this pre-chamber acts as a virtual “reservoir,” which minimizes underdosing and minimizes the amount of sample that must be supplied to the strip.

A phenomena in which a sample is applied to the opening of a test strip but hesitates to be drawn into the capillary is known as dose hesitation. As should be appreciated, this dose hesitation increases the time required in order to collect an adequate sample. Extending the hydrophilic reagent layer to the dosing end of the test strip and coating the underside of the chamber cover with a hydrophilic reagent reduces dose hesitation and promotes good wicking of the fluid sample into the capillary. Reducing dose hesitation in turn reduces fluid collection times and makes fluid collection easier.

The capillary channels in the embodiments illustrated in FIGS. 16-19 are flared or “Y-shaped.” The flared portion provides a wider target area for depositing a fluid sample onto the test strip. Further, the dosing end 36 of a test strip or biosensor is tapered to form a trapezoidal shaped profile in which a dosing edge 39 (FIG. 1) of the test strip is narrower than the width of the remainder of the test strip. The tapered end reduces the length of the edge that is wasted, i.e., the portion of the edge that sample fluid can contact but not enter the sample-receiving chamber. Additionally, the Y-shaped opening increases the target area for the fluid sample. The combination of this tapered end and flared portion produces a synergistic effect, in that it provides a test strip that will draw sample fluid into the sample receiving chamber no matter where along the dosing edge 39 the sample makes contact. This greatly reduces the chance of user error in dosing the strip. Further, it is not necessary to cover the entire opening with sample fluid. This feature greatly facilitates the use of small liquid volumes.

Turning now to FIG. 16A, a test strip or biosensor 300 is shown, which is substantially identical to biosensor 10 illustrated hereinabove. FIG. 16B illustrates a portion of a precursor or web 302, which corresponds to the structure shown in FIG. 12 after the chamber cover 240 and body cover 234 have been laminated. As shown in FIG. 16B, chamber cover 304 is clear and is spaced from body cover 306. Chamber cover 304 overlies the spacer layer, which has been formed with a series of voids 308. The voids include an elongated portion 310 and a bulbous portion 312. The bulbous portion can take a variety of shapes and comprises a shape which ultimately determines the shape of the flared opening, as described in more detail below. The spacing or spacer layer from which voids 308 are formed in FIG. 16B is similar to that shown in FIGS. 10-12, described above. That is, the void extends all of the way to the edge of the spacing layer and therefore defines a discontinuous periphery. In other words, the void extends to the edge of the spacing layer.

By contrast, as shown in FIG. 16C, an alternate set of voids 314 having continuous peripheries is formed in the spacing layer of precursor or web 315. Voids 314 comprise a light bulb shape, having bulbous portions 316 and elongated portions 318. In either case, the dosing edge of the test strip is formed by cutting through the precursor along dashed line 320 (FIG. 16B) or dashed line 322 (FIG. 16C), thereby forming the structure 260 shown in FIG. 13. As the cut is made, preferably by shearing across the web in the direction indicated in FIG. 13, the cut extends or spans across the bulbous portion of the void. Placement of the cut (lines 320 and 322) should be precise with respect to the longitudinal or lengthwise direction of the test strips ultimately formed from the web, such that the volume of the capillaries of the completed biosensors is consistent and within a tight tolerance. Of course, misplacement of the dosing edge affects capillary volume more when the capillary or sample receiving chamber has a flared portion than when it has parallel walls. Cutting along lines 320 and 322 not only forms the dosing end of the biosensors, but also forms the sample receiving openings of the test strips, which openings are aligned with the dosing edges. It should also be appreciated that while the dosing edge is shown in the illustrated embodiments as formed on the end of the test strips, it could also be disposed on a side, for example.

After the dosing edge of the web is formed, the web may be cut along lines 324 to form individual biosensors or test strips 300. As shown in FIG. 16A, biosensor 300 has a capillary or sample receiving chamber that includes a flared portion 328 that terminates in a sample receiving opening 330. An elongated portion 332 extends inwardly from the flared portion. As shown in FIGS. 16A-16C, the elongated portion is formed of substantially parallel walls that are defined by the void in the spacing layer, while the walls of the flared portion angle outwardly or laterally as the flared portion extends away from the elongated portion. The capillary or sample receiving chamber 326 communicates with vent opening 334 that is formed as a gap between chamber cover 304 and body cover 306, as also described elsewhere.

It should also be appreciated that, in preferred embodiments, the cut along lines 320 and 322 of FIGS. 16B-C also cuts through the reagent layer (see FIGS. 10-14), such that the reagent layer extends to and is coextensive with the dosing edge of the biosensors, as can be appreciated with respect to FIG. 2 discussed elsewhere herein. Since the reagent is hydrophilic, this advantageously promotes wicking of the sample into the biosensor and thus further discourages dose hesitation. Additionally, the cut forming the dosing edge also advantageously removes the most uneven portion of the reagent layer, thereby leaving behind an extremely flat and uniform reagent layer in the sample receiving chamber.

By way of non-limiting example only, the flared portion 328 can have a length of about 0.80+/−0.2 mm; a width at the sample receiving opening of about 2.9 mm; and the flared walls form an angle of about 110°. Other suitable dimensions for the sample receiving chamber are listed hereinabove. One of skill in the art should readily appreciate that the dimensions just noted are given merely as an example, and the dimensions of a biosensor falling within the limits of the appended claims could vary widely from those just given.

Indeed, many other shapes for the flared portion are possible. For example, turning now to FIGS. 17A-17C, biosensor 350 is similar to biosensor 300 shown in FIG. 16A, except that the flared portion 352 of sample receiving chamber 354 has curved walls rather than straight ones. In FIG. 17B, the voids 356 are formed as chalice shaped, whereas the voids 358 in FIG. 17C are shaped like keyholes. In either event, the cuts along dashed lines 362 form the dosing edge of the strips that will in turn be formed by cutting along lines 364.

Similarly, turning to FIGS. 18A-18C, biosensor 400 is similar to biosensor 300 shown in FIG. 16A, except that the flared portion 402 of sample receiving chamber 404 has a T-shape. In FIG. 18B, the voids 406 are formed as T-shaped, and the voids 408 in FIG. 18C are also T-shaped, having thinner cross-members of the “T.” In either event, the cuts along dashed lines 410 (FIG. 18B) and 412 (FIG. 18C) form the dosing edge of the strips that will in turn be formed by cutting along lines 364.

Referring to FIG. 1C, an optional notch 41 can be formed at the dosing end of test strip 10. Notch 41 may help reduce dose hesitation and provides a tactile sensation to the user that a finger or other alternate site is located correctly with respect to biosensor 10 when depositing a blood sample. The notch is disposed centrally with respect to the fluid receiving opening and is formed by cutting the same size and shape cut-out portions 43 and 45 in the aligned edges of covering layer 16 and base substrate 12, respectively. Cut-out portions 43 and 45 align with one another as shown.

FIGS. 19A-19C illustrate various alternate embodiments of test strips or biosensors having flared portions and/or notches that can be formed with the present invention. In FIG. 19A, an end of a biosensor 500 is shown in which the dosing end 502 comprises a flat or straight edge. Sample receiving chamber 504 includes a Y-shaped flared portion 506 leading inwardly on the strip to an elongated portion 508. An optional V-shaped notch 510 can be cut through the covering layer and base substrate. In FIG. 19B, an end of a biosensor 512 is shown in which the dosing end 514 comprises a curved profile. Sample receiving chamber 516 includes a curved shaped flared portion 518 leading inwardly on the strip to an elongated portion 520. An optional curved notch 522 can be cut through the covering layer and base substrate. Finally, in FIG. 19C, an end of a biosensor 524 is shown in which the dosing end 526 comprises a curved concave profile. Sample receiving chamber 528 includes a Y-shaped flared portion 530 leading inwardly on the strip to an elongated portion 532. An optional V-shaped notch 534 can be cut through the covering layer and base substrate.

EXAMPLE

By way of specific example, a test strip is formed based on the described method and using materials as follows. The bottom substrate is surface coated with a 50 nm layer of gold, and is slit to widths of 43-45 mm. Laser ablation (308 nm) is performed using a field size of approximately 40 mm×10 mm. The spacing layer assembly includes a spacing layer film of white Melinex™ 339, and a thickness of 0.1016 or 0.127 mm (4 or 5 mil). The bottom and top adhesives are an Adhesive Research Arcare 90132 adhesive at 0.0254 or 0.0127 mm (1 or ½ mil), sandwiched between release liners having a thickness of 0.0508 mm (2 mil). The capillary channels are formed with a width of 1.500 mm, +/−0.050 mm, and a pitch (spacing) of 9 mm, +/−0.150 mm.

The body cover 18 comprises a strip of Melinex 454, 453 or 339 material, 0.127 mm (5 mil) thick. The chamber cover 20 comprises a polyester or polyethylene naphthate material formed, for example, from Melinex 454 or 453, 0.1016 mm (4 mil) thick. As indicated, the chamber cover may be preferably treated or coated to have a hydrophilic underside adjacent to the capillary channel to promote wicking of the blood specimen into the channel. In a preferred embodiment, a Melinex 453 foil (4 mil) for chamber cover 20 is coated on its underside with a hydrophilic material 21, ARCare 90037 from Adhesives Research Inc. Preferably the chamber cover material is initially formed as a wider material, and is slit to the desired width after preparation.

TEST STRIP EXAMPLES

The following materials will be used in the strip: Base substrate layer 12 Melinex 329-9 mil or 329 - 10 mil Conductive Layer 26 Sputtered gold - 50 nm Lower Adhesive Layer 49 AR ARCare 90132 PSA - 1 to 0.5 mil Spacing layer 14 Melinex 329 or 339 - 4 to 5 mil Adhesive Layer 46 AR ARCare 90132 PSA - 1 to 0.5 mil Body Cover 18 Melinex 339 or 329 or 454 - 5 mil Chamber Cover 20 Melinex 339 or 329 or 454 - 4 mil Hydrophilic foil 21 ARCare 90037 Storage of Strips

Strips may be packaged in a variety of ways. For example, strips may be packaged into flip-top plastic vials (e.g., 10, 25 or 50 count). All containers include desiccant materials necessary to ensure acceptable shelf-life. Test strips preferably display a minimum shelf life of 18 months when stored between 4°-32° C. in tightly closed containers as provided.

Laser Sealed Manufacturing Technique

As discussed in the Background section above, adhesives for high volume production of test strips can be a significant cost both as a raw material and especially with respect to manufacturing costs. Instead of using adhesive, various techniques will be described below in which the laminate structures of the test strips are laser welded together. Test strips can be manufactured in an efficient and cost effective manner with these laser welding techniques. For example, the material costs associated with adhesives can be significantly reduced or even eliminated altogether. In addition, manufacturing issues created by the use of adhesives can be lessened or eliminated. As noted before, when adhesives are used to bond together the various layers and components of the test strip, adhesive sawdust can gum up on slitters that are used to cut the test strips. As a result, the slitters need to be shut down periodically for routine cleaning and maintenance, thereby lowering production rates. With the laser welding technique described herein, the issues associated with adhesives can be significantly reduced or even eliminated. Although the focus of the discussion for this technique will be forming capillary channels via laser welding, it should be recognized other components of test strips can be joined together via laser welding. For instance, as will be described below, all of the layers of the test strip can be laser welded together, thereby eliminating the need for adhesives. This adhesive free test strip can be for example achieved by lasing over most or all of the surface area of the laminate structure, or with spot welds spaced thereupon.

For purposes of the present invention, the underlying principle of laser welding two laminate layers together is that for any given type of laser, there are clear (or transparent) materials that will not absorb the energy of the laser (which as a result passes therethrough) and black (or absorptive) materials that will absorb this energy. As will be explained in further detail below, it is important to note that the terms “clear” and “black” refer to the laser-energy absorption characteristics of the materials, and not necessarily to the translucence, opacity or color thereof. It is desirable that these adjacent clear and black materials be essentially the same chemically as well as physically (e.g. same or nearly the same polymer base, same or nearly the same melting point). To seal two layers together, the laser is directed at the clear layer of a bi-laminate set up. The energy of the laser passes through the clear layer and is absorbed by the black layer. The black layer then melts and the heat from that physical reaction in turn melts the clear layer. The melted portions then mix and cool, leaving a weld. If the clear and black layers are significantly different in chemical and/or physical properties, this mixing may not be robust, thereby leaving a weak or otherwise insufficient weld.

The melting of the layers does not typically occur through the entire thickness of either layer. That is, the black layer is typically only melted to a certain depth therein for a given laser energy. Nevertheless, more than two layers can be laser welded together, either sequentially or simultaneously. As an example, three layers can be laser welded together to create a tri-laminate structure. For a tri-laminate set up, the laser can be directed at the outer layers individually, which can be done simultaneously or in sequence, depending on the configuration of the laser equipment and the webs of the laminates. For example, a first clear layer can be laser welded to a first side of a middle black layer, followed by turning the structure over for laser welding a second clear layer to a second side of the middle black layer. Alternatively, two lasers may be employed on generally opposite sides of the structure to laser weld the first and second clear layers to the black layer simultaneously (or nearly so). As a result, in a tri-laminate set up, both of the outer layers are typically clear, while the middle layer is black.

Notwithstanding the foregoing, it is possible for the black layer to be melted through its entire thickness in order to weld to the clear layers on opposite sides simultaneously, provided that the thickness of that layer is sufficiently thin or the energy of the laser is sufficiently high. In that case, a tri-laminate strip can be made in a single laser shot aimed at a clear outer layer that is welded to a black middle layer which in turn welds to a black or clear outer layer on the back side relative to the laser.

As also mentioned in the Background section, variations in hematocrit levels can affect the generated signal for a blood sample, and thus, it is desirable to manufacture a biosensor that is capable of reducing hematocrit interference in an easy, simple, and cost-effective manner. It has been found that physical separation via a microcapillary significantly reduces hematocrit. The microcapillary also reduces the required sample volume, which is desirable for consumers. However, due to the small dimensions involved with microcapillaries, there is a need for tight dimensional control during manufacturing. It was discovered that microcapillaries can be produced with high throughput, at low cost, and with tight tolerance control via laser welding. With laser welding, microcapillaries having volumes from 20 nl to 200 nl (or even smaller) can be produced in an efficient, consistent, and cost-effective manner. The micro-capillaries manufactured with this technique obviate the need for expensive surface-treated foils by utilizing the reagent as the hydrophilic modifier. Usually, these micro-capillaries for separating hematocrit are created when a bi-laminate structure is used in the test strip.

The principle is that red blood cells are relatively large, and thus if a capillary is formed by sealing two layers together that are held loosely together during the lasing sequence, the capillary height is high enough to allow fluid to enter via capillary action but is too low for red blood cells to enter. Thus, red blood cells congregate at the inlet of the micro-capillary channel. To further facilitate dosing in such a micro-capillary channel, a concave cutout of the top layer can be made such that the strip is contacted like a top-dosing strip but the reaction site is within the capillary channel.

A flow diagram 600 in FIG. 20 illustrates one example of a laser welding technique according to one embodiment that can be incorporated into the biosensor manufacturing technique described above with reference to FIGS. 5-19. It should be appreciated that this laser welding technique can be incorporated into other biosensor manufacturing processes besides the one described with reference to FIGS. 5-19. For example, it should be recognized that this laser welding technique should not be limited to the specific embodiments described herein such as ablated electrodes, slot die coated reagent layers, etc. That is, this laser welding technique can be adapted for other types test strips such as those with printed electrodes, dispensed reagents, vent holes, etc. Generally speaking, instead of using an adhesive, laser welds are used to secure the chamber cover layer 240 (FIG. 12) to the rest of the biosensor in the illustrated technique. The technique can be used to produce test strips via a continuous and/or discrete manufacturing process. For instance, large volumes of biosensors can be mass-produced with this technique via a continuous web process. Alternatively, individual test strips can be manufactured via the laser welding technique described herein.

In stage 602, the sets of electrodes 182, traces 184, and contact pads 186 (FIG. 7) are formed in the manner as described above. In one example, gold or other noble metal is sputtered or vapor deposited onto one side of a thin, clear electrode support foil that forms the base substrate 12. The support foil in selected embodiments can be about 200 μm thick, and the support foil can be for example a clear polycarbonate (PC) or polyester (PET) foil. To assist in the laser welding process, which will be described in detail below, the support foil can be clear or transparent relative to the type of radiation used in the laser welding, but as should recognized the foil can be opaque or semi-transparent in other embodiments. The now metallized surface or film 170 is laser ablated to form the electrodes 182, traces 184, and contact pads 186 along with other features, as is depicted in FIG. 7. Again, it should be recognized that the electrodes 182 can be manufactured via other techniques.

As noted before, the reagent layer 190 can be formulated so as to be hydrophilic, thereby eliminating the need for expensive surface-treated cover foils. During stage 604 (FIG. 20), the reagent layer 190 is deposited (and dried, if necessary). For example, an electromagnetic bellows (EMB) technique can be used which permits highly precise deposition of reagent to only where it is needed. EMB dispensing products are commercially available from Fluilogic OY of Espoo, Finland. Similarly, in other embodiments, laser printing, ink jet printing, laser ink jet printing, or even laser ablative techniques can be used, such as those described in WO 2007/033079 A2 to Home Diagnostics, Inc., which is hereby incorporated by reference. The reagent layer 190 for laser welding is typically discontinuous with one or more separate discrete sections. For instance, the reagent layer 190 in an embodiment depicted in FIG. 21 can be in the form of discrete reagent pads or sections deposited over the electrodes 182. Between the reagent pads 190, there are uncovered sections 605 that are not covered by the reagent. These uncovered sections 605 provide a clean contact surface between the base substrate web 188 and the chamber cover layer or web 240 for facilitating laser welding between layers. Any reagent present between the clear and black layers at the weld locations can tend to shade or block absorption of the laser energy on the absorptive or black layer. This in turn can tend to weaken the resulting weld between the layers and/or prevent proper sealing between the layers. The above-mentioned electromagnetic bellows technique is one suitable embodiment to create these discrete reagent pads 190 and uncovered sections 605, thereby minimizing the risk of the reagent weakening the welds through contamination. It is contemplated that trace amounts of the reagent 190 can be present at sections 605 to such a minor extent so as to not significantly affect weld strength and seal of the laser weld. It is also envisioned that sections 605 can be colored and/or treated in such a manner so as to promote laser welding as well. For example, sections 605 can be colored so as to absorb laser energy to promote laser welding, or sections 605 can be transparent so as to allow the laser energy to pass through in order to heat other surfaces, such as for example the chamber cover layer 240. A person of ordinary skill in the art will appreciate that whether the base substrate web 188 or cover layer 240 is the clear layer and black layer respectively is a matter of design choice, and the claims attached hereto shall not be limited (except as specifically recited) as to which structural element is clear versus black. Any specific reference or description in this regard is for exemplary purposes only.

As can be seen in the FIG. 21 exploded view, the spacing layer 196 (FIG. 10) has been eliminated. Instead, the chamber cover layer (second layer) 240 is directly attached to the base substrate web (first layer) 188. Generally, the chamber cover layer 240 is flat, and to form the sample receiving (micro-capillary) chamber 24, in certain embodiments the chamber cover layer 240 may be embossed in stage 606 to form channel indentations 607. The channel indentations 607 are spaced apart so as to coincide with the electrodes 182 and reagent 190 for the individual test strips. It should be appreciated that the channel indentations 607 can be formed in other manners besides through embossing, such as by stretching, folding, or otherwise deforming the chamber cover layer 240, for example. Moreover, the channel indentations 607 can be created during creation of the chamber cover layer 240 such that the channel indentations 607 are integral with the chamber cover layer 240. It is further contemplated that channel indentations 607 can be formed by applying additional components to the chamber cover layer 240, such as extra layers.

Stage 606 in other embodiments can be optional such that the channel indentations 607 are not required. For example, a chamber cover layer 240 without channel indentations 607 can be attached somewhat loosely to the web of base substrate material 188 in a manner such that a small gap is possible between the cover layer 240 and base substrate 188 that forms the sample receiving chamber 24. The two layers are laser sealed together without a spacer and without the channel embossed in the cover. Instead, the layers are brought together generally loosely and laser sealed. This allows for the formation of a rather thin capillary channel which can be used for hematocrit separation. As noted before, red blood cells are relatively large, and thus if a capillary is formed by sealing two layers together that are held loosely together during laser welding, the capillary height is high enough to allow fluid to enter via capillary action but is too low for red blood cells to enter. Thus, red blood cells congregate at the inlet of the capillary channel. In one form, the chamber cover layer 240 is slackened during attachment so as to create rather large sample receiving channels 24, but in other forms, the chamber cover layer 240 can be taut such that the sample receiving chambers 24 are relatively thin so as to minimize sample sizes as well as enhance hematocrit separation. It should be recognized that stage 606 can occur in a different order than is illustrated in FIG. 20. For example, stage 606 can occur before, during, and/or in between stages 602 and 604.

In stage 608, the chamber cover layer 240 is laser welded to the web of base substrate material 188. As mentioned previously, laser welding can produce micro-capillaries with high throughput, at low cost, and with tight tolerance control. Due to their small size, micro-capillaries in turn can reduce hematocrit interference.

As should be recognized, a device that produces any particles or electromagnetic radiation in a coherent state is considered a laser. In most cases, “laser” refers to a source of coherent photons, i.e. light or other electromagnetic radiation. As should be appreciated, the word “light” in the acronym Light Amplification by Stimulated Emission of Radiation (laser) is typically used in the expansive sense, as photons of any energy; it is not limited to photons in the visible spectrum. As a result, there are X-ray lasers, infrared lasers, ultraviolet lasers, and the like. For example, a microwave equivalent to an optical laser is commonly called a “maser”, but it should be recognized that for the purposes of discussion herein that masers are considered a type of laser. Although this technique will be described with reference to optical or near-optical-type lasers, it should be appreciated that other types of lasers can be used to weld the various layers together. In one particular form, the laser used for laser welding is an infrared (IR), solid-state laser. The laser that performs laser welding in stage 608 can be a continuous-type laser or a pulse-type laser. In one embodiment, the laser welding machine is of a type commercially available from Leister Process Technologies of Sarnen, Switzerland, but of course, other types of laser welders can be used.

When referring to the optical properties of the various layers during discussion of laser welding, the optical properties are in reference to the type of laser being used. For example, when a layer is transparent (or even translucent) in optical light but absorptive in ultraviolet light, the layer will be referred to as absorptive (or black) when an ultraviolet laser is used and transparent when an optical laser is used. To aid the reader in understanding this technique, the word “black” may be used herein to refer to a laser absorptive layer even when the layer in reality might not be actually black when viewed by an individual, but for instance, it might be another color or shade, such as grey, brown, etc. In a similar fashion, the term “clear” may at times be used herein to refer to laser transmissive layers that are transparent or translucent with respect to the laser beam such that the laser beam (at least in part) is able to pass through the layer. In general, during the laser welding of the various layers, one of the layers is more transmissive of the laser beam than at least one of the other layers and at least one of the other layers is more absorptive of the laser energy. This is distinguishable from certain known laser welding techniques in which the layers can be any material, where one layer is transmissive and the other layer is first coated with a substance designed to absorb the laser energy and adhere or otherwise weld the layers together. A commercial example is the CLEARWELD® process provided by Gentex Corporation of Simpson, Pa. In the present design, however, there is no need for coating a substance on any layer, and in most embodiments, this is generally a materials and manufacturing cost intended to be avoided.

When a layer is more absorptive than other layers, such as when a layer is black and the other layers are clear for an optical-type laser, the laser beam passes through the transmissive (clear) layers and is absorbed by the absorptive (black) layers. The resulting heat generated by the absorption of the laser beams melts all or part of the absorptive layer. The heat of the absorptive layer then melts the clear layer. The melted portions then mix and cool, leaving a weld. As noted before, if the clear and absorptive layers have significantly different chemical and/or physical properties, this mixing may not be robust, thereby leaving a weak or otherwise insufficient weld.

The chamber cover layer 240 can be laser welded to the reagent cover layer 188 in a number of manners. Looking at FIG. 22, the chamber cover layer 240 is spaced apart from a vent member 610 that covers the electrodes 182 and traces 184 so as to create the vent opening 34. As depicted, the chamber cover layer 240 is welded along weld lines 612 along the periphery of the end of test strip 614 as well as along the sample-receiving chamber 24. Like before, the ends of the test strips 614 can be trimmed along trim lines 262, and the individual test strips 614 can be separated along separation lines 264. After trimming, the weld lines 612 at least in part remain attached to the test strips so as to prevent body fluid from bypassing the sample-receiving chambers 24 during sampling.

During welding, the laser energy shines through a transparent (or semi-transparent/transmissive) layer and is absorbed by an absorptive layer, relative to the laser beam used, so as to create the heat that melts all or portions of the layers, thereby creating the weld lines 612. In one embodiment, the cover layer 240 is generally absorptive of and the base substrate web 188 is generally transparent relative to the laser energy utilized for welding. The cover layer 240 in one particular example is black (0.5% carbon black), and the web 188 is clear. Although the cover layer 240 generally absorbs the energy of the laser, the cover layer 240 in some forms can be visually transparent if a non-visible light laser beam is used. When the cover layer 240 is optically transparent (or semitransparent/translucent), the cover layer 240 can form a visualization window for determining fill sufficiency. In this embodiment, the laser beam is applied to the web side 188. When the beam is applied, the beam shines through the base substrate web 188, and the cover layer 240, which is opaque, absorbs the laser beam energy. The heat generated by the absorption of the laser beam energy causes the cover layer 240 and the web 188 to melt. Once cooled, the cover layer 240 and the web 188 fuse together along the weld lines 612 to create a strong, fluid tight seal. As mentioned above, the channel indentations 607 along with the weld lines 612 in one embodiment help to define the sample-receiving chamber 24, but in other embodiments, it is contemplated that the channel indentations 607 can be optional.

In an alternative embodiment, the cover layer 240 is generally transparent (transmissive), and the base substrate web 188 is generally absorptive (black). The laser beam in this embodiment is applied through the transparent cover layer 240 and absorbed by the absorptive web 188. The energy absorbed by the web 188 causes the web 188 and cover layer 240 to melt and fuse together at the weld lines 612. When the cover layer 240 is transparent in visible light, the cover layer 240 can be used to form a visualization window.

With the previously described embodiments, the laser beam is applied to a single side, but the laser beam in other embodiments can be applied to both sides either simultaneously or consecutively. For instance, both the cover layer 240 and the base substrate web 188 can be black, and laser beams are applied to the cover layer 240 and the web 188 at the same time in generally opposite relation. Moreover, the various layers do not need to be uniformly absorptive or transparent. In other words, the transmissive properties can vary at numerous locations on a layer. As one example, only a section of the layers that are intended to be welded are made absorptive, while other parts are made reflective or configured to scatter light so as to inhibit welding in areas that should not be welded, such as inside the sample-receiving chamber 24. It should be recognized that the various layers in whole or in part can be made absorptive of laser energy on a temporary or permanent basis, such as by applying an opaque ink to one or more of the layers. It is envisioned that a graphics label can be printed on or applied to the cover layer 240 as well as to other components. Various masking techniques can be used as well during laser welding to prevent or promote laser welding in various areas.

If so desired, other components can be attached via laser welding. For example, the vent member 610 can be attached via laser welding. Moreover, the vent member 610 can be attached before, during, or after the cover layer 240 is laser welded to the web 188. Laser welding can be used in conjunction with other forms for securing the various layers. For example, an adhesive can be used to secure a layer on a temporary basis before a laser weld permanently secures the layer. Once assembled, the test strips or sensors 614 are individually punched and packaged in the manners as described above. Alternatively, the sensors 614 can remain attached together to create a sensor tape for a multiple-test meter cartridge. Like the previous embodiments, the sensors 614 are punched or otherwise cut in such a manner that the sample receiving chamber 24 opens along an end edge of the test strip 614 for end dosing purposes.

FIG. 23 illustrates an alternate embodiment in which a cover layer or foil 616 stretches from the sample-receiving chamber 24 to near the contact pads 186 so as to cover the electrodes 182 and traces 184. Like the previous embodiment, the cover layer 616 is laser welded to the base substrate web layer 188 to create a two-layer or bi-laminate design. The web 188 and the cover layer 616 can be colored in the same manner as described above. That is, the layers can be alternately transparent and absorptive such that one of the layers allows the laser beam to pass through, while the other layer absorbs the laser beam. Instead of having weld lines 612 of the type illustrated in FIG. 22, the cover layer 616 in FIG. 23 has weld areas 618 that define the sample-receiving chambers 24. Vent openings 620 for venting air from the sample-receiving chambers 24 can be punched or otherwise formed in the cover layer 616. Optionally, a body cover 234 (FIG. 12) of the type described above can be attached over the cover layer 616 so as to partially cover the vent openings, thereby providing a fill indicator line. Once assembled, individual sensors 622 can be detached and packaged for individualized use, or the sensors 622 can remain attached in a sensor tape for a multiple-test meter cartridge.

It should be appreciated that laser welding can be used in a three (or more) layer sensor configuration as well, like the one illustrated in FIGS. 10-13. Instead of using adhesive, the base substrate web 188, spacing layer 196, and cover layer 240 are secured together via laser welding. Other components, like the body cover 234, can be laser welded in place as well. A flow diagram 624 in FIG. 24A illustrates a technique for laser welding the three layers together to form a tri-laminate structure. In stage 626, the sets of electrodes 182, traces 184, and contact pads 186 (FIG. 7) are formed in a manner such as is described above. In one example, gold is vapor deposited onto one side of a thin, clear electrode support foil that forms the base substrate (electrode support substrate) 12. The support foil in selected embodiments can be about 200 μm thick, and the support foil can be for example a clear polycarbonate (PC) or polyester (PET) foil. The now metallized surface or film 170 is laser ablated to form the electrodes 182, traces 184, and contact pads 186 along with other features, as is depicted in FIG. 7. It should be appreciated that the electrode patterns can be formed in other manners, such as via printing techniques, etc.

In stage 628, the reagent layer 190 (FIG. 8) is deposited over the electrodes 182 on web 188 in any suitable manner as described above with sufficient precision and definition so as to avoid leaving any more than trace amounts of reagent between base substrate 188 and spacer layer 196 at any location intended for laser welding. In one embodiment, between reagent pads 190, there are uncovered sections 605 that are not covered by the reagent. As should be recognized, the reagent layer 190 can be deposited in other manners as well.

Turning to FIG. 25, spacing (second) layer 196, which has pre-capillaries 220 a, 220 b, 220 c, etc., is applied to the web of base substrate material 188 in stage 630 and the layers are laser welded. The spacing layer 196 is approximately 100 μm thick PC or PET foil in one embodiment, but it should be appreciated that the cover layer 240 can have a different thickness and/or be made from different kinds of materials in other embodiments. However, even in this case, it is helpful that the various layers generally share similar chemical and physical properties so as to ensure adequate weld strength. In one example, the spacing layer 196 has a thickness that is high enough to allow fluid to enter via capillary action but is too low for red blood cells to enter, thereby enhancing hematocrit separation.

In stage 632, the cover layer 240 along with the body cover 234 is applied to the assembly 230 formed by the spacing layer 196 and web 188, as is depicted in FIG. 12, and is laser welded thereto. In one embodiment, the cover layer 240 is approximately 100 μm thick PC or PET foil. However, it should be understood that the cover layer 240 can have a different thickness and/or be made from different materials. Once the three layers are laser welded together, they create assembly 260, which is illustrated in FIG. 13. In one embodiment, the web of base substrate material 188 and cover layer 240 are generally clear or transparent, and the spacing layer 196 is generally black (0.5% wt./wt.).

In order to avoid particularly stringent tolerances in depositing the reagent layer 190 on the base substrate web 188 only within the dimensions of the to-be-defined capillary channel, in one embodiment (see flow diagram in FIG. 24B) the spacing layer 196 is applied to the base substrate web 188 (with the electrode patterns already formed thereon) and laser welded together prior to depositing the reagent layer 190. The cover layer 240 is then applied to the spacing layer 196 and laser welded together to create assembly 260. Thus the progression of stages is 626, 630, 628, 632. For a diagrammatic view of one possible continuous process embodiment of this progression, see FIG. 26B.

During laser welding according to FIGS. 24A and 24B, laser beams are applied to the web 188 and the cover layer 240 in a sequential fashion in order to laser weld the layers together. In other embodiments, however, the three layers can be laser welded generally simultaneously (see FIG. 24C). Thus, in stages 630 a and 632 a, the spacing layer 196 is applied to base substrate web 188 (with a formed electrode pattern and a reagent layer dispensed thereon in a sufficiently precise and defined pattern) and the cover layer 240 is applied to the spacing layer 196. In stage 634, the three layers are laser welded together generally simultaneously. As noted above, this can be achieved in at least two different ways. First, the three layers having been brought together may be laser welded as a result of multiple lasers applying laser beams to both sides in generally opposite relation. Second, the three layers having been brought together may be laser welded by a single laser configured to weld the three layers together at one time, wherein the spacing layer 196 comprises the more absorptive or black layer and one or the other of the cover layer 240 and base substrate web 188 comprises the transmissive or clear layer, wherein the other of layer 240 and web 188 may be either clear or black.

In the previously described examples, the web 188 and cover layer 240 were clear, and the spacing layer 196 was absorptive or black. However, other color combinations can be used. As an example, the web 188 can be black or more absorptive in comparison to the spacing 196 and cover 240 layers, which can be generally clear or more transmissive. After the spacing layer 196 is applied to the web 188 in stage 630, the spacing layer 196 is laser welded to the web 188. Once the spacing layer 196 is welded, the spacing layer 196 can be made less transmissive such as by printing a dark ink onto the spacing layer 196 or otherwise darkening the spacing layer 196 so as to promote laser welding of the cover layer 240. The relatively clear cover layer 240 is then laser welded to the now darkened spacing layer 196.

Various systems can be used for performing the above-discussed laser welding techniques. An example of laser welding system 640 for forming a bi-laminate biosensor will now be initially described with reference to FIG. 26A, which shows a diagrammatic view of the laser welding system 640. FIG. 26B shows a diagrammatic view of a laser welding system for forming a tri-laminate biosensor that will be described in greater detail below. As can be seen, the laser welding system 640 in FIG. 26A includes a cover supply reel 642 that supplies a cover layer web 644 that forms the chamber cover layer 240 and a base or substrate supply reel 646 that supplies substrate web 648 that forms the electrode support base substrate web layer 188. In the depicted embodiment, the cover layer web 644 is generally a black or laser absorptive layer, and the substrate web 648 is generally a clear or laser transmissive layer. However, it should be recognized that the properties of these webs can be reversed. That is, the cover layer web 644 can be generally clear, and the substrate web 648 can be black in other embodiments. In such a case, it should be recognized that the positions of the webs relative to the laser need to be swapped such that the laser is able to be absorbed by the black web. In the illustrated embodiment, the cover layer web 644 does not include any type of embossing so that the formed capillary channel is very thin so as to promote hematocrit separation, but in other embodiments, the cover layer web 644 can include embossing. The substrate web 648 in the depicted embodiment includes electrodes and deposited reagent. Along each web 644, 648, supply brakes or servodrives 650 control the tension and/or speed of the webs 644, 648 so that they remain properly synchronized for the laser welding process. If servodrives are used instead of brakes to control the unwinding speed of the reels 642, 646 at location 650, tension sensors will be typically required for both the input and output webs. Linear web guides 652 are used to guide the webs 644, 648 in the system 640.

The two webs 644, 648 are laser welded together at laser welding section 654. As can be seen in FIG. 26A, the laser welding section 654 includes a press roller 656 and a drum assembly 658. FIG. 27 illustrates a cross-sectional view of an embodiment of the drum assembly 658, and FIG. 28 shows a perspective view. With reference to FIG. 27, the drum assembly 658 generally includes a servomotor 660, a flexible coupling 662, a mask spindle 664, a bearing spacer 666, a mask wheel 668, and an acrylic wheel 670. The servomotor 660 is coupled to the mask spindle 664 through flexible connection 662. Opposite the servomotor 660, the mask wheel 668 is attached to the mask spindle 664, and the acrylic wheel 670 surrounds the mask wheel 668. The acrylic wheel 670, which freely rotates due to the bearing spacer 666, provides a contact surface for the substrate web 648 against the drum assembly 658. It should be appreciated that the acrylic wheel 670 can be made from other optically transparent materials besides acrylic. The bearing spacer 666 provides rotational support to the mask spindle 664 as the servomotor 660 rotates the mask wheel 668. As depicted, the mask wheel 668 has a series of mask sections 672 that mask various areas of the webs 644, 648 during laser welding. Each mask section includes a laser mask aperture 674 that defines the laser welded areas on the webs 644, 648. During operation, a laser is disposed inside the mask wheel 668, and the laser shines one or more laser beams through the laser apertures 674 so as to form a laser weld between the webs 644, 648 that coincides with the shape of the laser aperture 674. By rotating the mask wheel 668, the webs 644, 648 are able to be laser welded together in a high speed fashion. The laser apertures 674 in the depicted embodiment are physical openings in the mask wheel 668, but in other embodiments, the laser apertures 674 can be in the form of optically transparent sections. In the illustrated embodiment, the laser apertures are U-shaped so as to generally coincide with the laser welded section that surrounds the capillary channel of the biosensor. It should be recognized that, depending on the desired shape of the laser weld, the laser apertures can be shaped differently in other embodiments.

Referring again to FIG. 26A, a high-speed laser sensor 676 is disposed along the substrate web 648 just prior to the laser welding section 654. The high speed laser sensor 676 measures the speed and/or determines the relative position of the substrate web 648 by visualizing the electrodes on the substrate web 648. It should be appreciated that the position of the electrodes (or other components) and/or speed can be indirectly detected through target markings on the substrate web 648. With the laser sensor 676, the servomotor 660 of the drum assembly 658 is able to synchronize the rotation of the mask wheel 668 with the movement of the substrate web 648. This ability to synchronize rotation of the mask wheel 668 helps to ensure that the laser apertures 674 are properly positioned over the substrate web 648 during welding so as to avoid accidentally welding the wrong area. If possible, the laser sensor 676 should be placed close to drum assembly 658 to minimize the effect of stretching of the substrate web 648. In one particular example, the laser sensor 676 is an Aromat UZF321 Photometric Sensor (Panasonic Electric Works Corporation), but it should be understood that other types of sensors can be used.

At the laser welding section 654, the webs 644, 648 are squeezed between the press roller 656 and the drum assembly 658. A laser within the mask wheel 668 directs a laser beam towards the pressed together webs 644, 648. The laser beam shines through the laser apertures 674 as they rotate into position, while the mask wheel 668 masks the rest of the webs 644, 648 from the laser beam. Given that the substrate web 648 is clear, the laser beam from the laser aperture shines through the substrate web 648 and is absorbed by the black (or absorptive) cover web 644. The resulting heat causes the webs 644, 648 to melt and fuse together to form a welded biosensor web 678. Located downstream from the laser welding section 654, an inspection camera 680 inspects the biosensor web 678 for any defects as well as maintains process control. In one form, the inspection camera 680 is charge-coupled device (CCD) camera, but it can include other types of inspection devices. Downstream from the laser welding section 654, a master servodrive 682 maintains generally constant web speed, and the welded biosensor web 678 is wrapped around a rewind reel 684. The servodrives as well as other motors in the laser welding system 640 can come from various sources, such as from Rockwell Automation (Allen-Bradley).

FIG. 29 illustrates a front view of one variation to the laser welding system 640 described above with reference to FIG. 26A. FIG. 30 shows an enlarged perspective view of the laser welding section 654. Like before, the laser welding system 640 includes the cover supply reel 642, the substrate supply reel 646, supply servodrive 650, the laser welding section 654 with press roller 656 along with drum assembly 658, the master servodrive 682, and the rewind reel 684. FIG. 29 further illustrates a laser generator 686 disposed inside the drum assembly 658 for generating the laser beam and a laser adjustment mechanism coupled to the laser generator 686 for adjusting the relative position of the laser generator 686. Control/power systems 690 that are operatively coupled to the laser generator and other components of the system are also shown in FIG. 29. These control/power systems 690 are used to power and control the components of the system, such as the laser generator 686. A press roller actuator 692 is attached to the press roller 656 for actuating the press roller 656. Supply 694 and discharge 696 rollers are oriented in a triangular pattern relative to the drum 658 so as to guide the webs through the laser welding section in taut manner. The laser welding process in the system of FIG. 29 occurs in generally the same fashion as described above.

A laser welding process for a tri-laminate biosensor using similar techniques, principles and systems is illustrated in FIG. 26B. The laser welding system 698 in FIG. 26B shares numerous components in common with the laser welding system of FIG. 26A. For the sake of brevity and clarity, these common components will not be described in detail below, but please refer to their description above. One additional component of interest illustrated in FIG. 26B is reagent dispenser 699, which is used to dispense the reagent in a manner consistent with the discrete dispensing requirements set forth above.

FIG. 31 illustrates a top view of a first embodiment of a tri-laminate biosensor or test strip 700 that can be manufactured using the above-described laser welding techniques, and FIG. 32 shows a second embodiment of a tri-laminate biosensor or test strip 702 that can also be manufactured using the above-described laser welding techniques. As can be seen, both biosensors 700, 702 have a similar configuration with the exception of the electrode structure. The biosensor 700 in FIG. 31 has electrodes 704 that enter through the lateral sides of a sample or capillary chamber 706; whereas, the electrodes 708 of the FIG. 32 biosensor 702 enter through the end of the sample chamber 706. Both types of biosensors 700, 702 are laser welded together in the same fashion. For the sake of brevity and clarity, a technique for laser welding these tri-laminate biosensors will be described with reference to the FIG. 31 biosensor 700, but the same laser welding technique can be easily applied to manufacture the FIG. 31 biosensor 702.

FIG. 33 depicts an exploded view of the first tri-laminate biosensor 700, which includes a clear base substrate 710, a clear top substrate or cover layer 712, and a black capillary substrate or spacer layer 714. Again, it should be recognized that the various clear and black layers can be different in other embodiments. The base substrate 710 has electrodes 704, and at the sample chamber 706, the electrodes 704 are at least in part covered with a reagent. The spacer layer 714 has an opening 716 that along with the base substrate 710 and cover layer 712 form the sample chamber 706.

As alluded to before, the various layers of the biosensor 700 are typically supplied in rolls or reels so that the biosensor can be manufactured via a continuous process. FIG. 34 shows a perspective view of one such roll 718 of a base substrate web 720 that has a plurality of base substrates 710, which is shown in an enlarged view in FIG. 35. FIG. 38 shows a perspective view of a roll 728 that supplies a cover layer web 730, which is shown in an enlarged view in FIG. 39. A roll 722 in FIG. 36 supplies a spacer web 724 that forms the spacer layer 714 in the biosensor 700. Looking at FIG. 37, which shows an enlarged view of the spacer web 724, a plurality of sample cavity openings 726 that eventually form the spacer opening 716 are defined in the spacer web 724. It will be appreciated, however, that instead of openings 726 being pre-formed on spacer web 724, they may be provided just prior to the spacer web 724 being introduced to the base substrate web 720 in order to ensure that the openings 726 are properly positioned over the electrodes 704 at the required location for the sample chamber 706. With reference to FIG. 26B, a punching or cutting device (not shown) may be provided about spacer web 724 proximal to linear web guides 652 and servodrives 650. Sensors at drum assembly 658 may be configured to provide feedback to a controller controlling the rate of punching/cutting of openings 726 by the cutting device. Such sensors, for example, may determine the actual distance between electrodes 704 in adjacent biosensors in the web 720, and indicate to the controller appropriate locations for the openings 726 to be provided. As may be appreciated, this is an additional means for ensuring proper synchronization of all the webs being assembled for a tri-laminate embodiment of the present invention.

Turning to FIG. 40, the spacer web 724 is positioned to cover the end of the base substrate web 720 that contains the working, counter, and/or reference electrodes along with the reagent. The spacer web 724 is aligned with base substrate web 720 so that the sample cavity openings are aligned with the appropriate electrodes and reagent so as to form the sample cavity 706. With reference to FIG. 41, the cover layer web 730 is aligned slightly offset from the end of the sample cavity openings 726 so as to form vent openings 732 that are used to vent air from the sample cavities 706 when fluid is collected. In the illustrated embodiment, both the base substrate web 720 and the cover layer web 730 are clear, while the spacer web 724 is black. During laser welding, the laser beams shine through the clear base substrate 720 and cover 730 webs, and the laser beams are absorbed into the black spacer web 724. The resulting heat melts and fuses together the webs. FIG. 42 shows a top view of the U-shaped laser sealed region 734 that surrounds the sample chamber 706. Again, it should be recognized that that the laser sealing of the substrate web 720 and the cover layer web 730 to the spacer web 724 can occur simultaneously or sequentially. The excess web material is cut off along cutoff line 736 to arrive at a web of biosensors 700, which is shown in FIG. 43.

FIG. 44 illustrates a perspective view of a biosensor 740 according to another embodiment that is laser welded together in a manner similar to the technique described above, with a few minor exceptions noted below. Like before, the biosensor 740 includes a base substrate 742, the cover layer 712, and the spacer layer 714 that forms sample chamber 706. As can be seen, the base substrate 742 has an electrode structure 744 that slightly differs from the previously described one. Turning to FIG. 45, like the previous embodiment, the black spacer web 724 that forms the spacer layer 714 and the clear cover layer web 730 that forms the cover layer 712 are layered across a base substrate web 746 that forms the base substrate 742. The end edges of the base substrate web 746, the spacer web 724, and the cover layer web 730 are respectively indicated by lines 748, 750, and 752 in FIG. 45. The excess web material is removed at cut-off line 754 to form the opening of the sample chamber 706. One notable distinction, when compared to the weld pattern 734 in FIG. 42, the biosensor 740 in FIG. 45 is different. As can be seen, the weld pattern 756 in FIG. 45 stretches in a continuous manner.

While preferred embodiments incorporating the principles of the present invention have been disclosed hereinabove, the present invention is not limited to the disclosed embodiments. Instead, this application is intended to cover such departures from the present disclosure as come within known or customary practice in the art to which this invention pertains and which fall within the limits of the appended claims. 

1. A biosensor, comprising: a base substrate, at least one cover layer overlying the base substrate, wherein the base substrate and the cover layer cooperate to define a sample-receiving chamber; one of the base substrate and the cover layer being more transmissive than the other; a reagent positioned within the sample-receiving chamber; the base substrate and the cover layer providing an opening for the sample-receiving chamber along an edge therebetween; and at least one laser weld joining the base substrate to the cover layer to form the sample-receiving chamber.
 2. The biosensor according to claim 1, further comprising an electrode formed on the base substrate.
 3. The biosensor according to claim 2, wherein the electrode is a laser ablated electrode.
 4. The biosensor according to claim 1, wherein the less transmissive one is black in color.
 5. The biosensor according to claim 1, wherein the one that is more transmissive is substantially clear.
 6. The biosensor according to claim 1, wherein the base substrate is substantially clear and the cover layer is substantially black.
 7. The biosensor according to claim 1, wherein the base substrate is substantially black and the cover layer is substantially clear.
 8. The biosensor according to claim 1, further comprising a spacing layer over the base substrate, the cover layer overlying the spacing layer, the at least one laser weld comprising at least one laser weld joining the base substrate to the spacing layer and at least one laser weld joining the spacing layer to the cover layer, wherein the base substrate, the spacing layer and the cover layer so joined form the sample receiving chamber.
 9. The biosensor according to claim 8, wherein the cover layer and the base substrate are more transmissive than the spacing layer.
 10. The biosensor according to claim 9, wherein: the base substrate is substantially clear, the spacing layer is black, and the cover layer is substantially clear.
 11. The biosensor according to claim 1, further comprising a spacing layer laser welded between the base substrate and the cover layer to define the sample receiving chamber.
 12. The biosensor according to claim 11, further comprising: a body cover attached to the spacing layer; and the body cover being spaced apart from the cover layer to define a vent slot for venting air from the sample receiving chamber.
 13. The biosensor according to claim 12, wherein the body cover is laser welded to the spacing layer.
 14. The biosensor according to claim 1, wherein the reagent is hydrophilic.
 15. The biosensor according to claim 1, wherein at least the cover layer has a channel indentation to form the sample-receiving chamber.
 16. The biosensor according to claim 1, wherein at least one of the base substrate and cover layer are formed from polycarbonate.
 17. The biosensor according to claim 1, wherein at least one of the base substrate and cover layer are formed from polyester.
 18. The biosensor according to claim 1, wherein the cover layer defines a vent opening positioned to vent air from the sample receiving chamber.
 19. The biosensor according to claim 1, wherein the base substrate and the cover layer being laser welded around at least a portion of the periphery of the sample-receiving chamber
 20. The biosensor according to claim 1, wherein the base substrate and the cover layer have laser weld areas where the base substrate and the cover layer are welded together.
 21. The biosensor according to claim 1, wherein the sample-receiving chamber has a volume of between about 20 and about 200 nL.
 22. A biosensor, comprising: a base substrate; a cover layer; one or more laser welds in cooperation with the base substrate and the cover layer defining a micro-capillary chamber sized to reduce hematocrit interference in a blood sample; and a reagent disposed within the micro-capillary chamber to analyze the blood sample.
 23. The biosensor of claim 22, wherein the one or more lasers welds directly weld the cover layer to the base substrate.
 24. The biosensor of claim 22, further comprising a spacer laser welded between the base substrate and the cover layer to define the micro-capillary chamber.
 25. The biosensor of claim 22, wherein the base substrate has one or more electrodes for analyzing the blood sample.
 26. The biosensor of claim 22, wherein one of the base substrate and the cover layer is more absorptive of laser energy than the other at the one or more laser welds.
 27. A method, comprising: depositing a reagent on a base substrate; and laser welding together the base substrate and a cover layer to form a sample-receiving chamber of a biosensor that contains the reagent.
 28. The method of claim 27, further comprising: forming a vent that communicates with the sample-receiving chamber.
 29. The method of claim 27, wherein: one of the base substrate and the cover layer is more transparent than the other; and said forming the sample-receiving chamber includes laser welding through the one that is more transparent by directing a laser beam through the one that is more transparent.
 30. The method of claim 29, wherein: the base substrate is substantially transparent relative to the laser beam; the cover layer is configured to substantially absorb the laser beam; and said forming the sample-receiving chamber includes shining the laser beam through the base substrate and against the cover layer.
 31. The method of claim 27, further comprising: wherein the cover and base substrates have a common, co-extensive edge; and forming an opening for the sample-receiving chamber along the co-extensive edge of the base substrate and cover layer.
 32. The method of claim 27, further comprising: providing continuous webs of the base substrate and the cover layer; wherein said laser welding includes laser welding together the continuous webs of the base substrate and the cover layer to form a laminate, wherein the laminate includes multiple sample-receiving chambers containing the reagent; and forming an opening for each sample-receiving chamber along an edge of at least one of the base substrate and cover layer.
 33. The method of claim 32, wherein said laser welding includes: rotating a rotary-type mask as the continuous webs of the base substrate and the cover layer move thereby, wherein the rotary-type mask includes a plurality of mask apertures; and shining a laser beam through at least one of the mask apertures to form a laser weld between the continuous webs.
 34. The method of claim 33, further comprising: synchronizing speed of the web of the base substrate with the rotary mask so that the mask apertures are properly aligned during said laser welding.
 35. The method of claim 32, further comprising: dividing the continuous webs into multiple biosensor test strips.
 36. The method of claim 27, wherein: said laser welding includes laser welding around a perimeter of the sample-receiving chamber.
 37. The method of claim 27, wherein: said laser welding includes welding areas around the sample-receiving chamber. 